Banner GmbH, A-4021 Linz-Austria, Postfach 777, Banner Strasse 1, Tel. +43/(0)732/38 88-0, Telefax Sales +43/(0)732/38 88-21599, E-mail: office@bannerbatterien.com Editor: Günther Lemmerer, Marketing & PR

TECHNOLOGY NEWSLETTER No. 6 September 2011

During the manufacture of the newSHD PROfessional commercialvehicle battery, for the first timeBanner is using the innovative,continuous “ConCast” process for the production of negativeelectrodes. SHD PROfessional. For this new commercial vehiclebattery, which has emanated from thefirst fitting sector, the Austrian batteryproducer is employing pure calciumalloys on both the positive and thenegative electrode in a move thatprovides absolute zero maintenanceand increased storage capacity.During the summer of 2011, threebattery types in the 145Ah, 180Ah and225Ah categories were launched ontothe market. For details please see theBanner website www.bannerbatterien.com

ConCast electrode production. Banner is using the new “ContinuousCasting” (ConCast) process for theproduction of the negative mesh. Thisprocess combines the advantages of acast mesh (fixed, stable frame) withnarrow production tolerances andhigher process stability. In the SHDPROfessional, the new calcium alloyConCast electrodes replace the bookcast plates utilised to date. Investments of around EUR 3m. In 2009 and 2010, Banner invested around EUR 3 million in platemanufacture in the form of an in-house mesh production line in the form of anendless strip (ConCast) and aseparate pasting line (ConPast).

Guaranteed cold start power.The mesh and plate design has beenmodified, in order to ensure optimumcurrent conduction. This is possible dueto the fact that the mesh structure ismore precise than that resulting fromother processes. Consequently, coldstart performance is guaranteed in thewidest variety of operating conditions. ConCast line for mesh production. The starting-point for production is the melting of the calcium-lead alloy. This is then transferred to a rotating, roll castingmould in liquid form. During continuouscooling the metal hardens in the form ofan endless strip with double meshes.Following a quality check, 30,000meshes are rolled into so-called coils and at present, Banner is producingroughly 400,000 meshes daily.

ConPast line for plate production. Plates are subsequently manufactured in a second production phase. Output inthis area has been markedly increasedby means of new, high precisioncontinuous steel strip pasting withautomatic plate separation. 500,000plates per day are currently producedusing this process and in a parallelmove, lead oxide output has also beenexpanded. Know-how from joint venture partnerEast Penn/USA. This production process, which has beenthoroughly tested, has also recentlybecome operational at Banner’s jointventure partner East Penn in the USA.

Banner’s specialists were therefore able to refer to the experience gathered during the test phase and start-up, as well as the know-how of the company’s long-term partner.

The advantages at a glance Improved current conduction Mechanical mesh stability Narrow production tolerances High process stability levels Other operational possibilities. With immediate effect, ConCast electrodes are also to be used for the familiar Buffalo Bull SHD product line. Moreover, additional application possibilities include car batteries with electrodes subject to high current loads, e.g. the AGM Running Bull.

CONCAST ELECTRODE PRODUCTION FOR TRUCK BATTERIES