Curing and drying are critical steps in the lead-acid battery manufacturing process. These stages directly impact battery quality, consistency, and performance. To achieve optimal results, curing chambers must maintain precise temperature and humidity conditions—parameters that manufacturers carefully control and closely guard.
As battery production continues to evolve, manufacturers are responding to several global trends aimed at improving efficiency, safety, and product longevity.
Three Key Global Battery Manufacturing Trends
-Improved plate processing through robotic plate stacking to reduce manual handling and minimize worker exposure to lead.
-Shorter curing cycles that still promote advanced crystal growth and consistent plate formation.
-Smarter manufacturing solutions that improve product quality while increasing battery output per square foot of factory space.
Choosing the Right OEM Partner for Battery Production
Selecting the right OEM partner is essential to meeting these evolving demands. Manufacturers should look for an OEM with:
-A long-standing track record in lead-acid battery technology
-Experience supporting both large and small global operations
-Expertise in state-of-the-art curing chamber design
-The ability to develop custom curing ovens and drying chambers
Just as important is an OEM’s understanding of real-world production challenges. Improper curing chamber sizing, for example, can create significant bottlenecks. Undersized chambers restrict throughput, while oversized chambers increase cycle times and energy consumption. Proper chamber design helps reduce cycle time, improve efficiency, and lower operating costs.
Retrofit Solutions for Battery Furnaces and Ovens
- Oven Duct Face Retrofit Kit
A cost-effective alternative to purchasing new equipment, this retrofit optimizes airflow by modifying supply and return duct faces. Options include louver, high-velocity, cone, slot, or “H” nozzles to control airspeed and airflow patterns. Factory testing ensures improved airflow performance after installation.
- Roll Seal Door Retrofit Kit
Designed to replace manual swing or guillotine doors, this retrofit improves chamber sealing, insulation, safety, and aisle space. The roll seal door offers remote operation, self-adjusting seals, optional safety features, and a compact footprint.
- System Controls PLC Retrofit Kit
This upgrade enhances furnace performance through real-time data tracking, a user-friendly HMI, remote diagnostics, recipe storage, and communication with upstream and downstream equipment. Energy-saving features are also available.
- RTD to Vaisala (or Vaisala to RTD) Conversion Kits
ITS standardizes sensor technology across curing chambers to improve consistency, accuracy, and ease of maintenance—especially when newer systems differ from existing equipment.
- Honeywell Modutrol Motor to Belimo Actuator Conversion
Belimo actuators provide precise damper positioning feedback and eliminate mechanical linkages, reducing maintenance while improving reliability and alarm visibility.
- Exterior Manual Atomizer Cleanout Button with Flow Control
This retrofit allows operators to clean and inspect atomizers from outside the chamber. Integrated flow meters detect clogged or stuck-open nozzles, triggering alarms and reducing downtime.
- Hybrid Heater Retrofit
Combining electric heat during the cure cycle with gas heat during drying, this dual-heat solution provides tight temperature control while lowering energy costs compared to full electric systems.
- Custom Control Systems
Some custom control systems use Allen Bradley CompactLogix platforms. Systems are developed in collaboration with process, operations, and maintenance teams and can often be installed in as little as two days.
Evaluating Retrofit Opportunities
While retrofitting existing battery furnaces offers many advantages, each project should be evaluated individually. Equipment condition, upgrade scope, and cost-effectiveness must be carefully considered. A good equipment manufacturer will work closely with customers to identify the most practical and impactful solutions.
About International Thermal Systems
International Thermal Systems partners with battery manufacturers worldwide to design, install, and support advanced thermal processing equipment. Through continuous collaboration, ITS helps customers maximize efficiency, performance, and reliability.
ITS equipment is supported by a dedicated service team offering R&D, installation and startup, retrofits, repairs, preventative maintenance, and technical support—all performed by factory-trained technicians. The ITS parts department maintains a comprehensive inventory of replacement and spare parts to support all equipment.
📞 Contact the ITS team to discuss your current challenges and explore customized solutions:
