Sustainability culture leads to better battery manufacturing

Sustainability is a goal shared by everyone. Like many of its employees, customers, and members of the communities globally in which it is part, C&D Technologies is committed to playing a role in preserving the earth. Several initiatives have been integrated in an environmentally focused battery manufacturing approach that is shrinking our carbon footprint and helping bring long-term benefits for us all.

Since implementing "green" initiatives, C&D has reduced CO2e per battery produced by 6%. For the first half of 2026, we exceeded our goal of 2.5%, as many processes continue to improve operations. All these environmental benefits are running parallel with more efficient production of our industry-leading batteries, including our TEL High Temperature (TEL-HT), and Pure Lead Max and Pure Lead Plus AGM batteries, all of which utilize our award-winning Pure Lead Technology.

A corporate culture that starts at the very top has been a driver of this success. Support from executive management allows C&D to implement significant improvements at every manufacturing stage:

• Equipment. From lighting to robotics, each area of manufacturing is undergoing upgrades that are helping reduce energy consumption.

• Processes. New procedures complement the investment in advanced equipment to create efficiencies that are leading to lower utility costs and greater employee safety.

• Preventative Maintenance. Regular review of facilities is reducing equipment issues that lower production, increase costs, and can lead to added emissions and energy usage.

Investing in State-of-the-Art Equipment

Each of C&D's seven manufacturing facilities is undergoing upgrades with a focus on efficiency and sustainability:

Lighting. C&D is transitioning to LED lighting to lower electricity usage. Additionally, motion detectors and timers have been installed to conserve energy. This goes beyond conventional offices and includes remote areas, such as warehousing and storage, where people typically do not work for significant periods of time.

Pneumatic Systems. New air compressors and lines are being installed to shorten process times and reduce overall energy per part. Plus, using pneumatic systems limits on-site fuel combustion and direct process emissions, creating a cleaner manufacturing environment.

Assembly. Enhanced pasting and continuous casting equipment is being installed in multiple facilities. The new machinery is helping increase battery throughput, which in turn helps lower the CO2e per battery produced.

Robotics. Automated equipment is being implemented strategically. Early returns have shown efficiency increases of 10% or higher compared to manual processes. For example, robots are used in certain facilities for strap welding, which is the process of fusing the conductive metal straps or tabs to cells during battery assembly. Implementation of robots has also reduced employee injuries by limiting strenuous manual labor.

New Processes = Greater Efficiency

Energy consumption is a priority from the very beginning of each new process being rolled out, but it is not the only one. Safety is also a key consideration. Each decision is made based on the answer to one question - "Is this reducing our carbon footprint while also improving the well-being of C&D employees?"

To properly answer that query, evaluations are done to predict the benefits each automated process will bring. Analysis is also conducted to determine the best manufacturing floor layout, not just from an environmental standpoint but also ergonomically. This limits employee injuries by eliminating repetitive motion tasks, as well as physically demanding manual processes, helping create a healthier environment for workers.

Preventative Maintenance to Optimize Operations

All the effort and investment in new systems can be for naught if they are not properly maintained. Recognizing this, C&D has instituted monthly maintenance programs at its facilities to provide the checks and balances needed to achieve high throughput and sustainability benchmarks. Trained teams tour each department in every facility to make sure all equipment is operating as designed.

One example is the regular checks on the pneumatic systems. Even small leaks can lower the air pressure that will increase utility costs and slow throughput. Every leak is identified and repaired before it is a problem, minimizing the amount of electricity used.

Monthly maintenance evaluations are uncovering additional opportunities to improve operations. These processes are scheduled to be rolled out for continual sustainability and safety improvements.

Extending Sustainability to Customers

Our emphasis on sustainability also extends to C&D batteries and how they help customers achieve their ESG goals.

C&D Technologies' Pure Lead technology has proven to extend battery life compared to traditional VRLA batteries. The result is fewer battery replacement cycles. Pure Lead batteries can be used successfully at higher operating temperatures. Data centers can operate at a higher temperature, helping to achieve environmental metrics while also saving money on cooling costs as a result.

C&D's standard AGM and flooded batteries are also 98% recyclable. Plus, up to 50% of the reclaimed materials are used to produce new batteries.

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