CHAPTER-01

INTRODUCTION ABOUT THE

ORGANISATION AND INDUSTRY

1.1 Introduction:

A battery is an electrochemical device that can store energy in the form of chemical
energy. It translates to electric energy when the battery is connected in a circuit due to
the flow of electrons because of the specific placement of chemicals. It was invented
by Alessandro Volta, whereas Gaston Plante invented the rechargeable battery.

The battery consists of three elements: the negative side, the positive side, and
electrolyte (the chemical which reacts with both sides), as shown in the image below.
The electrolyte is used as an electron transportation medium between the anode and
cathode.

It works due to electrochemical reactions called oxidation and reduction. In this

reaction, electrons flow from one side to another side when the external circuit is
connected to the anode and cathode.

1.2 Industry Profile:

Batteries were an important origin and source of electricity energy before the rise of
power plants and electricity networks in the late era of 19th century. Consistent
innovation and improvements in battery technology field have enabled major as well
as most reliable advances in electricity – from past scientific discovery, research to
advent of modern gadget namely telegrams and telephones, which ultimately led into
laptops, mobile/cell phones, electric motorcycles, cars and many other electrical
devices.
Scientists, inventors, researcher and engineers have developed enormous useful types
of commercial batteries. “Wet rooms” are exposed containers containing partially
liquid electrolytes, metal electrodes. The exposed/Open containers are not suitable for
mobile or portable use electronic gadget. Wet rooms are widely used commercially in
telegraph gramophone and telephone systems. In late electric motor cycle and cars
used semi-sealed wet rooms batteries.

Because of massive use of batteries, these are classified into two main categories: (i)
primary batteries, also referred as rechargeable batteries, which are made to be
disposed after specified period of time or when it gets discharged; and (ii) secondary
batteries also named as renewable/rechargeable batteries, which are made to be
recharged and reused after batteries get exhausted. Primary batteries usually
composition of alkaline manganese batteries, carbon-zinc batteries, silver oxide
batteries, and primary lithium batteries.

Secondary batteries usually composition lead-acid batteries, lithium batteries, nickel-

cadmium batteries, and nickel-metal hydride batteries.

Lead-acid or secondary batteries have undergo to several advance progressive

changes in the technology, design wise and application of their invention, secondary
batteries have been the most widely used rechargeable made batteries in the world
today because of cost efficiency, adaptability, high battery capacity, product
reliability and safety as well as their wide use. They form more than 70.0% of the
global market for industrial batteries; based on sales in 2021 these batteries are also
highly recyclable eco-friendly. More than 95.0% of all secondary batteries are
recycled, pollution free and reused in the creation of new rechargeable batteries.
The battery industry in India, including automotive, maintenance free (SMF),
cylinders and lead acid, has experienced an annual growth rate of 25% per year.
Although China remains the largest battery market in the world, India is expected to
see the strongest sales growth in 2026. India battery demand from imports around the
world has increased and India is reacting to this. Production is also growing. The main
sectors whose demand is expected to increase in 2026 are solar power,
telecommunications, automation and energy conditioning given the growth in the
battery industry, Electronic Bazaar has decided to rate the 12 best battery
manufacturers based on their revenues for the 2021-22 fiscal year, which has been
confirmed by the Indian Government (MCA) website of the Ministry of Corporate
Affairs.

Some large companies cannot be included in the ranking because they refuse to share
their income data with us and their balance sheet cannot be founded on the MCA
website. We have not yet included companies that are exclusively/widely used in
making car batteries. Although this study is not comprehensive, it covers many large
battery manufacturers in India.

1.3 Battery Market segment:

The global battery market is expected to register a compound annual growth rate
(CAGR) of more than 9.5% during the forecast period of 2022-2028, reaching a value
of around USD 188.68 billion by 2028, up from USD 88.49 billion in 2022. The study
has been made by a Global industry analysis association. Market growth is driven by
increasing electricity demand, which is related to the increasing use of electronic
portable devices, Electronic gadget and devices namely smartphones, cellular
computers, and digital cameras continue to increase the demand and needs for
rechargeable batteries due to rapid growth in global technological enhancement.

Global industry analysis estimates that the global consumer market will cost nearly
US$ 39.9 billion in the year 2022, is projected to reach a revised size of US$52.5
billion by 2028, growing at compound annual growth rate (CAGR) of 4.2% over the
analysis period. The following key factors make a vital impact such as Market
expansion is stimulated, consumer income is increasing, and trends are in the use of
lithium polymer-based batteries in devices such as cell phones, increased battery
acceptance and expansion of the consumer market.

Economic development and growth will be continuing to drive primary (Industries,

manufacturer) and secondary consumer (ultimate end user) demand in the coming
years. In nowadays the increasing popularity of consumer’s battery devices and
consumer purchasing power will promote demand for effective and efficient high-
performance batteries. China has been led the global consumer battery market and
overwhelming vast consumer in terms of volume and growth. This is due to increased
consumer income, modern lifestyle, widespread industrialization and economic
growth.

Other emerging and sophisticated markets for high-performance consumer batteries

are South Korea, Srilanka, UAE, Qatar, India, Iran, Argentina, Norway, Poland and
Indonesia. Growth is being stagnate in mature markets such as Japan, U.K, and the
United States but in the EU will have slower growth rates in 2017. These markets will
be a vital part of the global consumer battery market, driven by increasing demand for
consumer electronic products for activated batteries.

1.4 Battery Industry in India:

An effort to develop and produce rechargeable/lead acid batteries in India has begun
at starting of the century. Until then, the requirements were fulfilled on a large scale
by organized imports, which really began after World War II. The decades from 1947
to 1956 witnessed and strengthen the rise of the Indian battery industry. Over
following three decades, Expansion of product line, range and production dense,
capacity in as per changes with market requirements. At present the Indian battery
industrial market exports over 15% of its production to various well-developed parts
of the world. The battery industrial market in India has evolved based on government
industry licensing policies and restrictions on the nature of the regional market. In
India, manufacturers in the (large) organized sector are needed to work with foreign
companies and import “knowledge”.

Government policy is also highly recommended activities are developed and

improvement of small-scale batteries sector and this approach has been monitoring
consistently followed for almost three decades. Knowledge import is only permitted if
there is no domestic technology. However, an exception is made if enormous export
potential is obtained or knowledge is imported. This will bring severe impact on the
quality, performance, cost of the device, durability and the ability to catch up with
battery development abroad.

Governments across the world are competing for a share of the global battery market.
With that market expected to exceed $125 billion annually by 2030, there is clear
motivation for India’s market participation. The Union cabinet’s in principal approval
of the National Programme on Advance Chemistry Cell battery storage is a strategic
step in positioning India to develop a thriving domestic battery industry and to capture
a large share of growing global energy storage market.

The Indian battery market 2021 was $ 4.47 billion and is expected to grow by
20.36% in value by 8.36% to $ 7.89% billion due to increase demand for cars,
continuous expansion of telecommunications infrastructure, increasing numbers of
solar energy projects and the growing IT industry. In India, production of two-
wheeled vehicles are forecasted to increase from 19 billion in 2020 to 50 billion in
2030, driving demand for lead acid batteries for tractors. In addition, the introduction
of the 5G network in the coming years will lead to the supply and expansion of new
telecommunication towers throughout the country, with a positive impact on the lead-
acid battery market over the next five years.
 2020 2025

1.5 Top 10 Battery Manufacturers in India:

1. Exide Industries Ltd.

2. Luminous Power Technologies Pvt. Ltd.

3. Amara Raja Batteries Ltd.

4. HBL Power Systems Ltd.

5. Su-kam Power Systems Ltd.

6. Okaya Power Pvt. Ltd.

7. Base Corporation Ltd.

8. Southern Batteries Pvt. Ltd.

9. Evoluate Solutions Pvt. Ltd.

10. True Power International Ltd.

Features of Battery Industry:

Type.
Voltage.
Discharge curve.
Capacity.
Energy density.
 Specific energy density.
Power density,
Temperature dependence.
Service life.
Physical requirements.
Charge/ discharge cycle.
Cycle life.
Cost.
Ability to deep discharge.
Application requirements.

Factors affecting battery performance and life:

The cathode/anode composition, its design, nature and characteristics of the oxide,
composition of paste, curing, formation and initial charging methods, concentration of
the acid, the separators, rate of discharge and temperature of operation.

Particle size, surface area, water and acid absorption rate, plate porosity,
crystallography of the oxide etc.

Battery maintenance and care:

 New batteries should be given a full charge before use.

 New deep cycle batteries need to be cycled several times before reaching full
capacity (25-100 cycles, depending on type). Capacity will be limited during
this period
 Battery cables should be intact, and the connectors kept tight at all times.
Always use insulated tools to avoid shorting battery terminals. Regular
inspection is recommended.
 Vent caps should be correctly installed and tight during vehicle operation and
battery charging.
 Batteries should be kept clean and free of dirt and corrosion at all times.
 Batteries should always be watered after charging unless plates are exposed
before charging. If exposed, plates should be covered by approximately 1/8″
of electrolyte (add distilled water only). Check electrolyte level after charge.
 The electrolyte level should be kept 1/4″ below the bottom of the fill well in the
cell cover. Click Here to see proper fill level.
 Water used to replenish batteries should be distilled or treated not to exceed
200 T.D.S. (Total Dissolved Solids…parts per million). Particular care should
be taken to avoid metallic contamination (iron).
 For best battery life, batteries should not be discharged below 80% of their
rated capacity. Proper battery sizing will help avoid excessive discharge.
 Battery chargers should be matched to fully charge batteries in an eight hour
period. Defective and unmatched chargers will damage batteries or severely
reduce their performance.

Functions of Battery Industry:

The chemical reactions in a battery involve the flow of electrons from one material
(electrode) to another, through an external circuit. The flow of electrons provides an
electric current that can be used to work.

Most industrial applications for flooded batteries are found in motive power, engine
starting, and large system power backup. Today, other forms of battery have largely
supplanted flooded batteries in small and medium capacity applications, but in larger
sizes flooded lead acid batteries continue to dominate.

Inputs for battery industry:

Typical automotive LIBs contain lithium (Li), cobalt (Co), nickel (Ni) in the cathode,
graphite in the anode, as well as aluminum and copper in other cell and pack
components.

Steps to manufacture a battery:

Initial quality control and electrode production.

Cell stacks assembly.
Drying, electrolyte filling, formatting, ageing and sorting.
Assembling cells into a battery.
ORGANISATION

Suryaa Battery Pvt. Started in 1998 in the cultural city of Mysuru. This device is
related to the production of batteries (automotive batteries and tube) under the brand
name “Suryaa Batteries”. Surya batteries are manufactured using the latest technology.
This plant is equipped with infrastructure for the production of all types of lead-acid
batteries. Factory and automatic machinery. Suryaa’s modern electrical and chemical
test laboratories meet international standards. Moto Surya is to provide customers with
free long-lasting batteries and meet the specific requirements of IS- 11369. The high-
performance and high-quality batteries from Suryaa are the result of the following
philosophy, where the principles of ISO-9001-2008 are strictly adhered to and adopted
in all aspects. Positive plates are a type of tabloid, which consists of a special low-
maintenance alloy with polyester gloves / tubes filled with lead oxide. Negative
adhesive plates with PE ENVELOP POCKET TYPE stored in a stable polypropylene
container with Spice Ltd and a suitable handle for easy lifting. They are equipped
with micro water traps to open traps and allow gas to escape and

passages to escape. Environmentally friendly with the right voltage regulation. The
frequency of refills is every 6 months. The refill tolerance is very good and accepts
very deep discharges of up to 10.5 pieces and this depends on the battery capacity.

The Suryaa Batteries maintains its manufacturing, research and development and
quality control activities using a well-equipped laboratory that tests the quality,
performance and lifetime of the raw materials used. These laboratories are also used to
provide important information to their engineers and chemist when formulating
sophisticated design and process modules to fully meet customer application
requirements.

Batteries made from Suryaa batteries meet different customer requirements, e.g. B.
Long cycle capability regardless of discharge depth and leakage current. Special grid
alloys are used to regulate fumigation and water loss, less corrosion, better
performance in slow climate conditions and very low interest resistance. The
production line uses the latest heat-sealing technology in polypropylene containers to
ensure product quality. The battery is sealed hot, tight against the seal and developed to
rotate the battery and withstand high vibrations.
The Suryaa battery product range mostly includes car batteries from 12 V 32 Ah to 12
V 200 Ah at 20 hours. Evaluate polypropylene tubular plates and special separators
from 12 V 20 AH to 12 V 200 AH at 10 hours C. Traction batteries are developed and
developed and produced exclusively according to customer specifications.

In short:

Suryaa Batteries Private Limited was incorporated in the year 1998.

With a dedicated staff that has more than two decades of experience in the battery
industry, they manufacture all types of lead-acid batteries for automotive and industrial
applications.

Our state-of-the-art manufacturing plant situated at heritage city, Mysuru has the latest
battery manufacturing equipment’s. The plant also has a sophisticated battery
laboratory and test house that makes the product efficient and excellent quality.