Battery Refurbishment Explained

REBATT UK have identified a market for the recycling and refurbishment of dry cell batteries under the Battery & Accumulaters Regulation 1991/157/EC and the WEEE Directive August 2005, Waste of Electrical and Electronic Equipment for recycling and re-use which includes portable equipment. Regulation 9 of the Landfill Directive July 2002 prohibits nickel cadmium, nickel metal hydride and lithium–ion from going to landfill.

REBATT UK refurbish power tool batteries for Wakefield Metropolitan District Council, Leeds Building Agency, Huddersfield & Kirklees Council Barnsley MBC plus many trade customers.  We have successfully completed battery trials on the production lines for MG Rover Group, BMW/Mini, IBC Vehicles and Honda Manufacturing. We already refurbish battery tooling for Honda Manufacturing with plans to refurbish and recycle power tool batteries for BMW/Mini in April 2006.

The process involves the opening of the battery case and the removal of the ‘spent’ cells.  Screwed cases can be opened relatively easily with an indefinate life span providing the cases are not damaged. This process can be applied to any cordless DC battery pack and rechargeable battery back-up system which uses Nickel Cadmium, Nickel Metal Hydride and Lithium-ion battery packs.

A new cell pack replaces the old one and the cases are re-closed and tested  before being supplied back to the customer for re-use at a lower cost yet still have the same performance and reliability. The cells and re-processing of the cases carry a 12 month guarantee under normal conditions of use and application.

When the sealed plastic cases have reached their ‘full life-cycle’ the battery packs are re-opened and the cells removed. The casings are supplied to plastic re-processors and the spent cells transported to a special recycling plant in France for recycling as an available resource and then supplied to cell manufacturers for reuse.

This method is known as the ‘closed loop system’ or landfill diversion because the battery casings or spent cells do not go to landfill which has been the situation for many years.

The Battery “life cycle” can be increased through the refurbishment process up to three times, even longer with screwed battery casings  The life cycle or reuse process means the rechargeable battery packs can be recovered and refurbished [re-celled] before being sold back to the customer for re-use.

Battery refurbishment is used on secondary [re-chargeable] cells - Nickel Cadmium, Nickel Metal Hydride and Lithium - ion which can be applied to many applications. For example, power tool batteries, portable voice data used in order picking and stock control/inventory. 

The most recent developments for refurbishment are the Adflo battery which is used to circulate the air around the welding mask and the Stryker and Maxi Driver II batteries which are used in National Health Service in Operating Theatres.

A complete new cell pack replaces the original using higher capacity cells, the cases are re-closed using the existing casings and component parts. The battery pack is supplied back to the customer for re-use at a lower cost, saving the customer 20% on net prices. When several batteries or more are refurbished on the same order a further 10% discount is given. Volume orders sometimes will qualify for further discounts when the customer is looking for price breaks.

The pricing structure has been implemented to persuade the customer to refurbish the battery pack rather than purchase a new battery which is 30% - 50%  more expensive. The cells and assembly process have a 12 month guarantee under normal conditions of use. The battery pack is cleaned on the outside and any light scratch marks are removed using a buffer.

Ultrasonically sealed battery packs that are opened and closed a number of times can have a limited life span due to the removal of material to open the casing and the separation of the glue to reuse the casing.