Indianapolis, Indiana, USA — A new end‑to‑end solution promises higher productivity, lower risk, and improved material efficiency for battery manufacturers expanding grid manufacturing capacity. Battery manufacturers investing in new lead‑acid capacity now have access to a fully integrated grid manufacturing solution designed to simplify production while improving efficiency and quality. CONTIGRID™, a continuous manufacturing platform developed through close cooperation between industry leaders Eagle and Hazelett, brings melting, casting, rolling, coiling, and grid stamping together into a single, optimized process. It reduces operational complexity and execution risk while delivering higher throughput.
Unlike traditional grid operations that rely on multiple suppliers and disconnected process steps, CONTIGRID™ consolidates the entire lead grid value chain into one coordinated system, from melt to stamped grid. The result is a streamlined production flow that minimizes handoffs, stabilizes quality, and improves material utilization across the line.
“Battery manufacturers are under increasing pressure to add capacity quickly while controlling cost and risk,” Eagle’s Chief Technology Officer Jeff Troxel said. “CONTIGRID™ has been developed to address exactly that challenge. It delivers a proven, fully integrated manufacturing solution instead of a collection of individual machines.”
Built on Decades of Real‑World Experience
CONTIGRID™ is the culmination of more than 25 years of hands‑on collaboration between Eagle and Hazelett in wide‑strip casting and grid stamping. Since supporting the first wide‑strip casting line in 1997, the engineering teams behind the platform have been involved in more than 35 production lines worldwide, gaining deep practical experience across every stage of lead grid manufacturing.
That experience spans engineering development, system integration, commissioning and startup support, and close familiarity with all major equipment suppliers and specifications. By consolidating this expertise into a single cooperative offering, CONTIGRID™ provides manufacturers with a single accountable partner and one fully aligned solution.
“Our customers told us they wanted fewer interfaces and more accountability,” Troxel explained. “By bringing decades of operational knowledge into one integrated platform, we’re able to reduce project risk while accelerating time to stable production.”
One Continuous Process from Melt to Stamped Grid
At the core of CONTIGRID™ is a continuous, closed‑loop production flow that integrates alloy melting and control, continuous strip casting, precision rolling, and automated coiling and material handling. Each stage is engineered to support the next. This eliminates bottlenecks and unnecessary material handling that can degrade quality or reduce yield.
The system extends beyond strip production. It includes progressive grid stamping, inspection, aging, preparation for pasting, and integrated vacuum chip return and remelt systems. This holistic approach allows manufacturers to optimize their entire grid operation rather than improving individual steps in isolation.
“Every part of the process was designed as part of a whole,” Troxel said. “When melt rates, casting speeds, rolling configuration, and stamping throughput are all balanced from the start, manufacturers see more predictable operation and better overall performance.”
Simplifying Capital Projects with a Single Point of Responsibility
One of the defining features of CONTIGRID™ is its one‑stop‑shop project model. Customers work under a single commercial contract. This contract covers end‑to‑end project management, optimized equipment integration, material validation, and process and grid design guidance. This approach reduces coordination effort, shortens project timelines, and minimizes execution risk during capacity expansions.
A detailed analysis underpins every CONTIGRID™ design, ensuring proper equipment integration, efficient labor utilization, and optimized uptime. Key variables, including melt pot capacity, alloy control strategy, caster speed, rolling schedule, and press utilization, are evaluated early in the project to deliver the best combination of footprint, throughput, and return on capital.
Business Case Delivered
“CONTIGRID™ delivers high-throughput performance. This enables manufacturers to achieve production levels equivalent to 4-5 million batteries per year in positive plate operations — maximizing output while maintaining consistent quality.”
Beyond productivity gains, the platform delivers material savings through optimized strip and grid design, emissions reduction through tighter process control, and improved downstream performance extending into pasting operations.
“CONTIGRID™ is about more than making grids,” Troxel concluded. “It’s about giving battery manufacturers a strategic manufacturing advantage, one that improves efficiency, sustainability, and long‑term competitiveness across the entire plant.”