HOW OUR BATTERIES ARE MADE:

Step1 image 1

From start to finish, DIXON Premium Batteries are made with the very best
quality for our customers in mind.

In accordance with our environmental responsibility to effi ciently recycle batteries, our battery recycling plant situated in Vereeniging, South Africa                                                                                   breaks down used batteries, separates the usable materials from the waste, and uses those materials to produce new DIXON Premium Batteries.
Used batteries are crushed in a hammer mill and separated into lead, lead oxide, polypropylene and
polyethylene materials.

Step 2 Image 2

Metallic lead particles and lead oxides are melted into metallic lead in a
rotary furnace. All the waste generated during the recycling proc ess is safely disposed of in
an approved hazardous waste site. The metallic lead from the rotary
furnace is poured into block moulds and allowed to cool.

Step 3 Image 3

Metallic lead particles and lead oxides are melted into metallic lead in a
rotary furnace. All the waste generated during the recycling process is safely disposed of in
an approved hazardous waste site. The metallic lead from the rotary furnace is poured into block moulds
and allowed to cool.

Step 4 Image 4 & 5

These lead blocks are then re-melted in large lead pots. A sample is taken to determine the metallic composition of the
lead. The lead is then alloyed or refi ned, depending on the factory requirements.

Step 5 Image 6

These lead blocks are then re-melted in large lead pots. A sample is taken to determine the metallic composition of the
lead. The lead is then alloyed or refi ned, depending on the factory requirements.

Step 6 Image 7 & 8 & 9

Alloyed lead is used in the grid caster to manufacture grids.

Step 7 Image 10

Lead cylinders cast from refi ned soft lead are then fed into an oxide mill, which produces lead oxide.
The lead oxide is mixed in a paste and is then pasted into the grid to form a battery plate.

Step 8 Image 11 & 12

Once they are cured and casted, the battery plates are enveloped and are stacked with negative battery plates
to form battery cells.

Step 9 Image 13 & 14

Polypropylene from the battery breaker is processed through an extruder machine and is cut into fi ne pellets, which are used of manufacture the battery cases, covers
and handles.

Step 10 Image 15 & 16 & 17

Polypropylene from the battery breaker is processed through an extruder machine and is cut into fi ne pellets, which are used
to manufacture the battery cases, covers and handles.

Step 11 Image 18

Our hands-on team then ensures the edges of the battery cases, handles and
covers are perfectly smooth and expertly fitted.

Step 12 Image 19

Lead straps are formed in a mould to weld all the positive and negative battery plates together to form a cell.
Individual cells are then passed through a short circuit tester to check if any electrical shorts exist between the
positive and negative plates.

Step 13 Image 20

A squeeze welder welds each cell to the cell opposite it to form a circuit.

Step 14 Image 21

The battery lid is sealed onto the battery case in a heat sealer machine.

Step 15 Image 22

Battery terminals are welded to the battery cell post extensions.
The batteries are pressure tested to make sure there are no leaks present.

Stpe 16 Image 23

The batteries are formed in a charge bay.
Acid levels are checked and adjusted.
A heavy current discharge test tests all our batteries prior to dispatch.

Step 17 Image 24

A date code is engraved on each battery.
The batteries are then labelled and ready for sale.

Step 18 Image 25 & 26

Our effi cient packing team then uses state-of-the-art equipment to carefully package each and every battery. This
ensures DIXON Premium Batteries arrive at their destination in the same pristine condition they left the factory.

Step 19 Image 27 & 28

DIXON Premium Batteries are transported in a proudly branded fl eet of DIXON trucks that deliver our batteries
throughout South Africa, Botswana, Zambia and Namibia.