The performance and reliability of a lead-acid battery are determined long before the product reaches the finishing line. Curing, acid formation, and filling are among the most critical stages in the process, yet they are also some of the hardest to control. Extreme humidity, rapid temperature changes, and aggressive sulfuric acid environments create conditions where traditional sensors struggle, data becomes unreliable, and process control suffers.
To help battery manufacturers address these challenges, Vaisala is hosting a technical webinar. The webinar will explore how better control of humidity, temperature, and acid concentration can help prevent quality losses from the earliest stages of lead-acid battery manufacturing. Vaisala experts Maria Nyman and Bea Siuro will walk through the key pain points in curing and in acid formation and filling, showing how robust, fit-for-purpose measurements can support more stable, repeatable processes. You will gain insight into why standard humidity sensors tend to drift or fail in curing chambers operating at around 90–98% relative humidity, where condensation and harsh conditions are unavoidable. By contrast, you will see how Vaisala’s measurement technology is designed to withstand constant high humidity and chemical stress, helping you maintain trustworthy data rather than constantly troubleshooting instrumentation.
Accurate, stable measurements also enable more effective use of existing equipment. When curing and formation chambers are instrumented with reliable sensors and transmitters, they can be run closer to optimal setpoints instead of relying on overly conservative margins put in place to compensate for poor data. This supports better chamber utilization and can help reduce energy consumption, as well as the use of natural gas and water, while keeping product quality under tight control. Non-drift, low-maintenance measurement tools further reduce the need for frequent manual checks and recalibration, helping to minimize downtime and free up engineering resources.
A central focus of the session is the transition from manual, intermittent acid sampling to automated, continuous concentration measurement. Traditional manual checks of sulfuric acid are slow, expose personnel to hazardous liquids and fumes, and provide only snapshot information. By replacing these steps with inline Vaisala Polaris™ process refractometers, manufacturers can gain real-time concentration data directly from pipelines and tanks. This supports safer working practices, higher levels of automation, and faster, data-driven process adjustments. Instead of waiting for lab results, operators can keep acid concentration within the desired range throughout dilution, formation, and filling based on continuous measurements.
The relationship between sulfuric acid density and electrochemical performance is well understood in lead-acid chemistry. The webinar will discuss how tight control of acid density in the typical 30–38% range supports consistent electrochemical behavior in the finished battery, from formation efficiency to in-service performance and lifetime. Inline concentration measurement, combined with robust humidity and temperature monitoring, gives production and process engineers a stronger foundation for achieving uniform plate formation, predictable electrolyte properties, and more repeatable quality from batch to batch.
Fast, reliable measurements also play a key role in optimizing plate quality, lead formation, and load permeation. When humidity, temperature, and acid concentration are all monitored accurately and in real time, deviations can be detected early and linked to downstream quality observations. This helps teams move from reactive troubleshooting toward proactive, data-driven process optimization. Over time, such an approach can support higher yield, more consistent product performance, and more efficient use of materials and utilities.
This webinar is ideal for production and process engineers in lead-acid battery plants who are directly responsible for curing, formation, and filling steps. It is equally relevant for quality and operations managers who aim to improve consistency and yield, and for plant managers seeking to reduce energy, water, and acid waste while maintaining high quality standards. Anyone involved in optimizing these critical stages will benefit from the practical examples and best practices shared by Vaisala’s experts.
To learn how controlled humidity, temperature, and acid concentration can support better batteries, safer operations, and more efficient production, register now for Vaisala’s “From curing to filling” webinar on March 12, 2026.
