May 23, 2024

Battery Rebuild Service: A Viable Option to Extend Battery Life

As technology has advanced at a rapid pace in recent years, our reliance on batteries has also increased exponentially. From smartphones to laptops to electric vehicles, batteries play a key role in powering our devices. However, battery life is limited and they need to be replaced after a certain period of usage. While replacing batteries can be an expensive proposition, battery rebuild services offer an economical alternative to get more life out of old batteries.

Understanding BatteryRebuild Process
The Battery rebuild service basic process involved in rebuilding a battery includes replacing worn out or damaged components like plates, separators and electrolyte while keeping the outer casing. A thorough cleaning and inspection is done first to identify components that need replacement. New plates made of pure lead are installed along with high-quality separators and distilled water or acid as electrolyte. Proper sealing is done to prevent any leakage. Performance testing is carried out before shipping the rebuilt battery.

Key Components Replaced
Battery plates are one of the key components that get worn out with time and cycling. Lead acid batteries usually have thin lead grids as positive plates and thicker lead grids as negative plates. Over time, active material on these plates sulfates and capacity reduces. Rebuilding services replace these worn-out plates with new pure lead plates to restore capacity. Separators also get damaged with time, allowing short-circuiting between plates. Quality multi-layer polyethylene or fiberglass separators are installed. Electrolyte level and composition needs replenishing as well to regain power and performance.

Varied Battery Types Supported
Battery rebuild services support reviving most types of lead acid batteries including starting-lighting-ignition (SLI) batteries for cars and trucks, deep cycle batteries for RVs, golf carts and boats as well as stationary batteries for telecom towers, solar installations and UPS systems. While automotive and motorcycle SLI batteries are the most common, rebuilders have expertise and capability to refurbish even large deep cycle or stationary batteries up to the industrial scale.

Step-by-Step Rebuilding Process
Following are the main steps involved in professional battery rebuilding:

Inspection and Cleaning: Batteries are carefully inspected, measured and cleaned to remove dirt, dust, corrosion and sulfate build-up. Open circuits are identified.

Plate Removal and Replacement: Damaged or worn-out plates are removed and new pre-formed lead plates matching original specifications are installed.

Separator Installation: High-density poly/fiberglass separators are installed between new plates to prevent short-circuiting.

Formation and charging: New plates are subjected to formation charging to break them in and maximize surface area for capacity.

Addition of Electrolyte: Freshly prepared leady electrolyte is added for maximum voltage and performance.

Sealing and Assembly: Batteries are sealed properly and all components assembled with high precision.

Performance Testing: Rebuilt batteries undergo rigorous testing under load to ensure specified CCA, reserve capacity and life.

Shipping and Warranty: After successful testing, batteries are shipped or delivered with a performance warranty.

Proper rebuilding with quality controls ensures rebuilt batteries can potentially last years like a new pack with nominal investment compared to replacements. Let’s look at some key advantages of opting for battery rebuilding.

Advantages of Battery Rebuild over Replacement

Cost Savings: Rebuilding batteries works out to be 70-80% cheaper than buying new replacements. Labor costs are also lower compared to factory production.

Environment Friendly: Rebuilding minimizes waste generation and preserves natural resources by reusing the existing lead alloy structures rather than manufacturing from scratch.

Extended Service Life: When rebuilt professionally with high grade materials, batteries can last up to 5+ years, much longer than the average life of 1-3 years for an original battery.

Retains original design: Rebuilt batteries maintain the same form factor and mounting footprints to fit right into the original equipment without changes.

Warranty Backed Performance: Reputable rebuilders offer performance warranty for rebuilt batteries equivalent to that of new packs.

Sustains original battery potential: Reconstruction restores the full rated CCA, reserve capacity and life cycle potential embedded in the original battery design.

The main demerit is a rebuilt battery may have slightly lower CCA ratings and life expectancy versus an absolute new unit. However, for the huge savings on cost and environmental sustainability, battery rebuilding remains a very attractive proposition for commercial and industrial users.

Closing Thoughts
In Battery rebuild service summary, with rapid progress of new battery technologies like lithium-ion, rebuilding lead acid batteries may not remain commercially viable forever. However, for the next 5-10 years still, a sizeable existing base of SLI and industrial batteries are amenable to rebuilding to extract further value. When done by experienced professionals, battery rebuilding can deliver up to a decade of service at a fraction of new replacement costs. It serves as a practical, economical and eco-friendly option for extending battery life sustainably.

1. Source: Coherent Market Insights, Public sources, Desk research
2. We have leveraged AI tools to mine information and compile it