Production Process

The technology developed inside S.I.A. laboratories of R&D is an integral part of the quality management system, compliant to ISO 9001 norm; the maximum electrical and mechanical performance, and reliability of the batteries are guaranteed to the customers.

The team is constantly researching more performant solutions aligned with the increased energetic requests of the market. Maximum attention is given to the production process and to the market scenario. 

The chemical tests on leady oxide and on the electrode plates follow the most strict protocols existent in literature:

• Analysis on the degree of oxidation
• Measure of the granulometry
• Analysis of the reactivity of the oxide in sulphuric acid
• Measure of the amount of "free lead" on pastes after curing
• Analysis of the sulphates concentration on the dry active material

The electrical tests on the batteries are carried out following the valid and updated technical norms recognized internationally (EN 50342-1, EN 50342-6, EN 60254-1, ecc.) with accurate and reliable laboratory equipments. Few routinary tests on production lots:

• Capacity in 5, 10 and 20 hours.
• Measure of the crancking current (CCA, Cold Cranking Current)
• Self-discharge tests
• Water consumption experiments
• Cycle Endurance tests

Ingots of Soft Lead (purity of 99,98%) are reduced into small cylinders that are treated inside our ball mills. The mixture of lead oxide and pure lead (so called "leady oxide") obtained represents the key factor for preparing a performant electrode active material suitable for a wide range of applications. The purity degree of the soft lead and the severe check of the operative parameters, guarantee a high and stable quality standard of the lead paste produced. The lead oxide obtained is stocked in silos for curing, before its utilization in the next steps of the production process.

The treatment of the soft lead guarantees a good control on the pastes produced. The reactivity of the system is maintained constant, as the macroscopic characteristics of the powder of leady oxide (granulometry, density, etc.); this represents the first step to monitor the crystalline structure of the paste during plates curing.

The technology of expanded metal allows the production of a grid with high performance for starting/ignition. The particular tridimensional mesh is ideal for having high corrosion resistance and a good adhesion of the active mass. The lead-calcium alloy utilized makes the batteries assembled with very low self-discharge and Maintenance Free.
Pastes and curing of the plates are thinked for obtaining high cranking currents offered, a good capacity retention and a high cycle durability.

The recipes and the treatment of the plates are under continuous study by laboratory of Research & Development for reaching higher quality standard and a higher competitiveness.

The truck line is characterized by a high cycles resistance and an optimum resistance to vibration thanks to the Casting technology used for grids production. The radial grid design, allows the placing on high quantities of active material on them, and batteries obtained are very performant under the point of view of the current crancking.

The recipes and the dosage of the active materials are projected with attention to the application involved. With this kind of technology, also light traction plane plates are produced: high density pastes, increased thickness of the plates, and curing treatments applied are special. With these treatments, S.I.A. light traction batteries are very resistant to deep-discharge cycles.

A lot of models and batteries formats are produced with semi-authomatic lines. From the envelope-machine for the electrode groups preparation, to COS (Cast-on strap), to the electro-welding station and box-lid thermal welding one, the human contribution of operators is fundamental for increasing the quality of the products.

The production capacity of S.I.A. plant can reach from 1.000.000 to 1.300.000 batteries per year, depending on the distribution of the models assembled.

The formation/first charging of the batteries is carried out through bulk o one-spot process, where dry batteries are filled with acid with a target density, and charged with automated charging programs. The formation is followed under all the points of view, maintaining under control the most important process parameters, including the internal temperature of the battery.

Depending on the technology used for batttery assembly, the formation current can be impressed in different ways: pulsed, under controlled ramp, through charge/discharge micro-cycles. The plates of the batteries are charged and activated in the best way, for guaranteeing high electric characteristics and a maximum energetic efficiency.