Podcast · Learning

Batteries Demystified by Ramesh Natarajan

by Ramesh Natarajan · English · Learning

Mr. Ramesh Natarajan has over four decades of experience in the domain of lead acid battery designing, manufacturing, testing, marketing, and servicing with a special focus on trouble shooting peculiar problems. His continuing passion for learning about lead acid batteries and enthusiasm to share te

New episodes: Every two weeks
Typical length: 10 min
Latest: 28 Jul 2026
Language: English

Latest episode

28 Jul 2026 · 12 min

85. Experience is Valuable… Until It Starts Replacing Standard Operating Procedures (SOPs)

In every process-oriented industry, we invest heavily in technology, automation, and quality systems. Yet one of the biggest causes of quality issues often has nothing to do with machines or materials. It is the gradual drift away from “Standard Operating Procedures” (SOPs)—often by the most experienced employees who believe they know a “better” or “faster” way. Have you experienced situations where overconfidence or informal shortcuts compromised quality? How does your organization ensure th...

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Earlier episodes 29 most recent

21 Jul 2026 · 8 min
84. Can Environmental Regulations Hurt The Battery Industry?
How do we balance environmental responsibility with industrial competitiveness? Because true sustainability is achieved not by making business difficult, but by creating regulations that reward compliance, encourage investment, and ensure a level playing field for every stakeholder. The lead-acid battery industry has already demonstrated that a mature circular economy is possible. The lithium-ion industry is now building its own recycling ecosystem. Policymakers have a unique opportunity to l...
8 Jul 2026 · 11 min
83. A Case Study – Positive Grid Corrosion
In this episode of my podcast, I share a real-life case study from a recent visit to the automotive battery industry. A manufacturer was experiencing many warranty claims due to positive grid corrosion. To solve it, they strengthened the grid by adding extra horizontal and vertical wires. The corrosion issue improved—but a new set of problems emerged. Battery capacity reducedOEM customers were unhappy with the heavier batteryAssembly processes had to be modifiedRecharge time became longerOne ...
1 Jan 2026 · 26 min
82. The Write Inheritance: How Words Build Legacies
In this inspiring episode of The Write Inheritance, industrial marketer Bejoy Peter sits down with Ramesh Natarajan, well-known author and battery industry expert to explore the powerful connection between writing, influence, and legacy. From factory floors to life as a best-selling author, Ramesh shares how his journey through the world of batteries sparked stories that charge minds and move hearts. Together, Bejoy and Ramesh unpack the creative process, the discipline of writing amidst dem...
30 Oct 2025 · 7 min
81. Stop Losing Power: The Connection Mistake Most Forklift Users Make
“Bolt it, or burn it?” That’s the question I explored in my latest podcast episode. Both bolt-on and weld-on cell traction batteries have their pros and cons — but the real difference shows up in: How they’re serviced,How they’re maintained, andHow long they last.Most people think bolt-on cells are “better and convenient,” but do they realize the equalization step can make or break the battery’s life? Listen in as I explain why ease of service doesn’t always mean better performance. SHARE YOU...
18 Sep 2025 · 17 min
80. 11 Guidelines for Success in the Battery Industry
🔋 What does it *really* take to succeed in battery manufacturing? It’s not just about chemistry and machinery. In my latest podcast episode, I discuss 11 powerful (and often overlooked) guidelines that separate thriving battery businesses from the ones that quietly disappear. This isn’t your typical technical talk — it’s about the real challenges, the silent killers of profitability, and the strategic decisions that matter most. Whether you're a manufacturer, entrepreneur, or industry enthusi...
8 Jun 2025 · 6 min
79. Bubbles on pasted plates – Why? A case study.
Bubbles on Pasted Plates… but why? Everything looked normal. •Same paste formula. •Same raw materials. •Same paste chemical additives •Same machine settings. But over 50% of the plates were getting rejected. Right after pasting. Before even reaching the drying oven. The QC team tried everything—tweaking the mix, rechecking materials, and recalibrating equipment. Still, the problem persisted. 👉 Then came a phone call. And a video. 🔍 What followed was a surprising discovery 🎧 In thi...
28 May 2025 · 8 min
78. Deep Discharge Of Lead-Acid Batteries Explained
Battery manufacturers specify the end-of-discharge voltage based on battery design and application. Any discharge below the end of the discharge voltage is termed a deep discharge. Deep discharges, especially when more frequent, lead to battery capacity loss and degradation of the active material. Batteries subjected to deep discharges fail prematurely. In the case of lead-acid batteries, deep discharges damage both the positive and negative electrodes. Sporadic and infrequent low volt...
25 May 2025 · 31 min
77. Are EVs Fitted With Lithium-Ion Batteries The Future Of Passenger Transportation?
Electric vehicles, or EVs as they are more popularly known, are a sunrise sector with a lot of government encouragement so that car buyers shift to EVs from Internal Combustion Engine vehicles. Internal Combustion Engine vehicles are referred to as ICE vehicles. EV buyers are lured by the fuel cost savings that will accrue to them when they buy an EV. However, any fuel cost savings accrued to an EV owner have to cover the higher cost of EVs compared to ICE vehicles, insurance premi...
24 May 2025 · 10 min
76. Lithium-Ion Battery Room Design Recommendations
Did you know that Lithium-Ion batteries are not similar to lead-acid batteries in terms of safety and handling procedures? The popularity of lithium-ion batteries has resulted in the spawning of many dealers, traders, and assemblers of cells and modules. This is a good development, but many entrepreneurs are unaware of the risks associated with lithium-ion batteries. Hence, I considered doing this podcast episode focusing on the facilities to be incorporated in the battery rooms, keepin...
19 May 2025 · 10 min
75. Sulfation In Lead Acid Batteries - Explained
Sulfation is a necessary part of the operation of lead acid batteries and is a phenomenon which is less understood. The various types of sulphation and the problems due to sulphation when a battery is misused have been clarified. The characteristic signs of sulphation have also been explained. You are welcome to write to me with your comments and suggestions. The contact details are on the website, www.RameshNatarajan.in SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connectedJoin...
30 Apr 2025 · 9 min
74. Possible Cause of Self-Discharge of Automotive Batteries
A battery manufacturer who manufactures automobile batteries faced a problem with their self-discharge. This issue started to arise after he began exporting his batteries. This is another Case Study. Join me as I walk you through the various steps before I zero in on the problem caused by an unexpected reason. This thrilling episode will make you assess your process. Another unmissable episode for all lead-acid battery manufacturers. To hear this enchanting case study, please tune in to...
29 Apr 2025 · 14 min
73. Will Lithium-Ion Batteries Replace Lead Acid Batteries?
I agree with many people within the battery industry and with battery users worldwide that Lithium Battery technology will usher in a change in the availability of battery technology. A lot of people hold the view that Lithium batteries will replace lead-acid battery Technology. Is it a far-fetched view or an impossible dream?Is it an unrealistic and non-achievable vision?To hear my views on this topic, please tune in to this episode of my podcast.SHARE YOUR FEEDBACK Visit, www.RameshNa...
23 Apr 2025 · 11 min
72. Necessity Of Using Dry Charged Plates To Make Good SMF Batteries
The manufacture of SMF batteries is not as easy as that of flooded electrolyte vented type batteries. One main reason for this is that an SMF battery has limited electrolyte, and the specific gravity of this electrolyte cannot be measured. Is there a way to ensure the required consistent specific gravity in all the cells while maintaining a constant volume of sulphuric acid? How can a good SMF battery be manufactured? To learn how to make long-life, high-performance SMF batteries, pleas...
10 Apr 2025 · 8 min
71. How a Shortage of Antimony is Affecting the Lead Acid Battery Manufacturers
A shortage of Antimony metal is causing significant disruptions in the battery world, and the impact goes beyond battery manufacturers. So, what’s happening? The price of lead itself hasn’t skyrocketed, but the real trouble lies in the shortage of antimony, a key ingredient in the alloy used to make lead-acid batteries. And when something critical goes missing from the supply chain, chaos follows! Now let us understand why there is a shortage of Antimony. SHARE YOUR FEEDBACK Vis...
11 Feb 2025 · 5 min
70. A Calculator to Calculate Void Volume Before Manufacturing Positive Tubular Plates
Are you manufacturing tubular plate batteries? Are you adding more active material but still getting lower capacity? Are you facing issues with tubular bag bursting? Are your batteries heavier than branded ones but failing during the warranty period? Click on the link below to access the calculator: https://battech.rameshnatarajan.in/calculator SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connectedJoin my network on LinkedIn to engage on social mediaView m...
10 Feb 2025 · 5 min
69. ट्यूबलर प्लेटों को सही ढंग से भरने के लिए एक कैलकुलेटर
क्या आप ट्यूबलर प्लेट बैटरी बना रहे हैं? क्या आप अधिक सक्रिय सामग्री भर रहे हैं और फिर भी कम क्षमता प्राप्त कर रहे हैं? क्या आपको ट्यूबलर बैग फटने की समस्या का सामना करना पड़ता है? क्या आपकी बैटरियां ब्रांडेड बैटरियों से भारी हैं लेकिन वारंटी अवधि के दौरान खराब हो रही हैं? कैलकुलेटर तक पहुंचने के लिए कृपया निम्नलिखित लिंक पर क्लिक करें: https://battech.rameshnatarajan.in/calculator SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connectedJoin my network on Linked...
28 Jan 2025 · 36 min
68. Mix or Match? The Science of Lignosulphonates in Battery Manufacturing
Have you ever wondered which of Vanisperse A, Vanisperse HT 1, or Vanisperse DCA is more suitable for the lead-acid batteries that you manufacture? Do you know which of these lignosulphonates is better suited for batteries that gas vigorously and which is better for those that are overcharged and remain at high temperatures? Are you mixing two types of lignosulphonates—Vanisperse A and Vanisperse HT1—and is it acceptable to do so? Is Borregard’s product meant for CCA only, or is it also meant...
19 Jan 2025 · 37 min
67. Modifying the Alloy to Improve its Corrosion Resistance and Cycle Life
Are you using Lead Calcium Tin Aluminum alloys?Are you facing issues during casting due to grid softening?Are you getting fewer cycles when you use this alloy?Are your batteries failing during the warranty period due to alloy?Mr. Ali Alagheband discusses modifying the alloy to improve its corrosion resistance and cycle life. SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connectedJoin my network on LinkedIn to engage on social mediaView my videos on my Youtube Channel to get furt...
14 Jan 2025 · 6 min
66. A CASE STUDY - Cracking the Case of the Shrinking Gauntlets: A Battery Industry Puzzle
I received a call from a tubular bag manufacturer who shared that he received complaints about the tubular bags shrinking after pickling. He had even received photographs from the battery manufacturer, which clearly showed the tubular bag had dislocated from some of the spines at one end of the plate. He was confident his tubular bags were perfect and wanted me to talk to the battery manufacturer about the correct pickling procedures. After seeing the photographs, I guessed the...
9 Jan 2025 · 16 min
65. Launch of Mobile App for BaTTech
In this episode, we unveil the BaTTech Mobile App, a groundbreaking tool designed to empower battery manufacturers. With its intuitive calculator series, the app simplifies complex calculations, enhances operational efficiency, and drives sustainable innovation. Join us as we explore the app’s features, its impact on the industry, and how it’s set to transform battery manufacturing worldwide. SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connectedJoin my network on LinkedIn to eng...
7 Jan 2025 · 7 min
64. एक केस स्टडी - सिकुड़ते गौंटलेट्स के मामले को सुलझाना: एक बैटरी उद्योग पहेली
👉 पिकलिंगकेलिएरखीगईपॉजिटिव ट्यूबलर प्लेटों के गौंटलेट/ट्यूबलर बैग सिकुड़ क्यों रहे थे? 👉 ट्यूबलर बैग का सिकुड़न एक समान क्यों नहीं था? 👉 इस समस्या से निकलने के लिए प्रक्रिया में क्या बदलाव आवश्यक था? 👉 ट्यूबलर बैग निर्माता का कौन सा प्रश्न अप्रत्याशित था और मैं उसका उत्तर नहीं दे सका? SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connectedJoin my network on LinkedIn to engage on social mediaView my videos on my Youtube Channel to get further insights of Lead Acid Batteries
25 Nov 2024 · 5 min
63. Dipping Of Filled Tubular Positive Plates In Ammonium Sulphate – A Substitute To Pickling?
👉 Are Ammonium Sulphate dipped plates similar to Sulphuric Acid pickled plates? 👉 Can the Ammonium Sulphate dipping procedure be accepted as an alternative to the Sulphuric Acid pickling procedure? 👉 Is it acceptable to process the Ammonium Sulphate dipped plates like Sulphuric Acid pickled plates? 👉 Are subsequent processes different for Ammonium Sulphate dipped plates and Sulphuric Acid pickled plates? SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay conne...
14 Nov 2024 · 9 min
62. एक केस स्टडी - कैसे एक निर्माता 20% वारंटी दावों से बाहर हो गया।
👉 यह एक ट्विस्ट के साथ केस स्टडी है। ✅ आज का एपिसोड इस बात पर है कि क्या नहीं करना है! ➡️ आम तौर पर, एपिसोड जानकारीपूर्ण, ज्ञान-साक्षात्कार या सलाहकार प्रकार के होते हैं। मेरा मतलब यह है कि वे इस बात पर ध्यान केंद्रित करना चाहते हैं। ➡️ मैं आपको एक कहानी बताता हूँ। मेरा मतलब है कि यह एक सच्ची घटना है जिसने मुझे हैरान कर दिया। मुझे एक समस्या का समाधान करना था और समाधान मुझे नहीं मिल रहा था। अंत तक सुनें और आप घटनाओं के मोड़ से आश्चर्यचकित होंगे। ➡️ मुझे एक बैटरी निर्माता का फोन आया जिसने...
12 Nov 2024 · 8 min
61. क्या बैटरी बनाने के लिए पुनर्चक्रित सीसे का उपयोग करना संभव है?
➡️ बहुत सारे बैटरी वितरक, डीलर और कुछ मामलों में निर्माता भी हैं जो ग्राहक को बताते हैं कि वे बैटरी बनाने के लिए शुद्ध सीसे का उपयोग कर रहे हैं जबकि प्रतिस्पर्धी पुनर्चक्रित सीसा का उपयोग कर रहे हैं । ➡️ अब यह वास्तव में सच नहीं है। ➡️ बड़े स्थापित बैटरी निर्माताओं सहित एसएमई बैटरी निर्माताओं द्वारा उपयोग किया जाने वाला सभी बैटरी पुनर्चक्रित सीसा से होता है। बैटरी निर्माण के लिए बाजार में जो सीसा घूम रहा है, उसका अधिकांश भाग पुनर्चक्रित सीसा से है। ➡️ लेकिन किसी...
24 Oct 2024 · 11 min
60. Battery regeneration: a fashionable trend or workable model?
✳️ Is it practically possible or economically viable? ✳️ ▶️ When a battery stops performing well or even fails within its warranty period, it must be thoroughly checked before being scrapped. ▶️ As a battery ages, its performance naturally declines—much like the human body. ▶️ Speaking of which, here's a helpful analogy: think of your body with all its organs. As we age, our organs wear down over time. Some of them deteriorate gradually, while others may completely fail. ▶️ ...
20 Oct 2024 · 6 min
59. Pickling Of Tubular Positive Plates – A Blunder To Be Avoided
✳️ A Case Study: Another one on - What Not To Do! ▶️ When a tubular bag or gauntlet fails in a battery – is it always due to the tubular bag? ▶️ As a battery manufacturer, where does the investigation of the battery warranty claim caused due to the tubular bag failure end? ▶️ As a tubular bag manufacturer what is to be done when repeated claims arise from one or few battery manufacturers blaming tubular bags as the reason for battery failure? ▶️ How important is manufacturing process kn...
24 Sep 2024 · 34 min
58. Business Strategy For The Battery Industry - In Conversation With A Reputed Business Coach Mr. Biman Gandhi
You must have heard the buzzword BUSINESS STRATEGY. Is it just another buzzword that big companies throw around? What does it mean for smaller businesses? How can a strategy help small and medium-sized businesses grow and stay ahead of the competition? In today’s episode I shall try to break it down in simple terms, talking about what strategy is, why it’s important, how you can create a strategy and use it effectively in your own business. Whether you're new ...
24 Sep 2024 · 5 min
57. Segregation & weighing of plates before assembly – Does it help?
Are you weighing your battery plates before assembly? Are you under the impression that weighing unformed plates and segregating them helps improve your battery quality? Is it just another fad that you are blindly following? Is it useful & affordable for small and medium businesses? In today’s episode, I shall try talking about this popular phenomenon that adds no value and is an unnecessary costly exercise. SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connectedJoin my ...
30 Jul 2024 · 11 min
56. Case Study – The Mysterious Case Of Paste Shedding From Cured Pasted Battery Plates
Lead-acid batteries, a process-oriented product, is not as simple to manufacture as it seems. Battery manufacturers must know What Not To Do which is as important as What To DoThis podcast episode is a case study with a twist.The battery manufacturer was losing tons of money for a simple fault of hisThe identification of the problem was difficult.Listen till the end and enjoy this interesting episode SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connectedJoin my netwo...

About Batteries Demystified by Ramesh Natarajan

Batteries Demystified by Ramesh Natarajan is a English learning podcast from Ramesh Natarajan. Melo plays each episode straight from the publisher's own feed — no ads added, no account needed — and remembers where you stopped, in this browser only.

Publisher: Ramesh Natarajan
Language: English
Category: Learning
New episodes: Every two weeks
Typical length: 10 min
Latest episode: 28 Jul 2026
Feed: RSS — paste into any podcast app
Apple Podcasts: podcasts.apple.com/podcast/id1626940036

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