Batteries Demystified by Ramesh Natarajan

Hosted by Ramesh Natarajan

Science Education

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Episodes

Latest episode

Jul 2026

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EN-US

About the show

Mr. Ramesh Natarajan has over four decades of experience in the domain of lead acid battery designing, manufacturing, testing, marketing, and servicing with a special focus on trouble shooting peculiar problems. His continuing passion for learning about lead acid batteries and enthusiasm to share technical details related to batteries, chargers, and the various equipments which use batteries, has resulted in this venture, comprising of a series of Podcasts. His website www.RameshNatarajan.in also has Articles, FAQ's and Videos in addition to the contact details. Your comments and suggestions are most welcome.

Listen to episodes

60 recent

July 28, 202612 min

85. Experience is Valuable… Until It Starts Replacing Standard Operating Procedures (SOPs)

In every process-oriented industry, we invest heavily in technology, automation, and quality systems. Yet one of the biggest causes of quality issues often has nothing to do with machines or materials. It is the gradual drift away from “Standard Operating Procedures” (SOPs)—often by the most experienced employees who believe they know a “better” or “faster” way. Have you experienced situations where overconfidence or informal shortcuts compromised quality? How does your organization ensure that SOPs are consistently followed while still encouraging continuous improvement? Having spent over 42 years in the lead-acid battery industry, I have witnessed how seemingly insignificant deviations from SOPs can eventually lead to inconsistent quality, increased warranty claims, higher manufacturing costs, and dissatisfied customers. Experience is invaluable, but it should strengthen SOP compliance—not replace it. In my latest podcast, I share why SOPs are much more than documents—they are the collective wisdom of an organization, built on years of experience, trials, failures, and continuous improvement. I also discuss practical ways organizations can strengthen SOP compliance without discouraging innovation. I would love to hear your thoughts on this topic. #Leadership #Quality #Manufacturing #Operations #StandardOperatingProcedures #SOP #ContinuousImprovement #OperationalExcellence #QualityManagement #LeanManufacturing #IndustrialEngineering #BatteryIndustry SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connected Join my network on LinkedIn to engage on social media View my videos on my Youtube Channel to get further insights of Lead Acid Batteries

July 21, 20268 min

84. Can Environmental Regulations Hurt The Battery Industry?

How do we balance environmental responsibility with industrial competitiveness? Because true sustainability is achieved not by making business difficult, but by creating regulations that reward compliance, encourage investment, and ensure a level playing field for every stakeholder. The lead-acid battery industry has already demonstrated that a mature circular economy is possible. The lithium-ion industry is now building its own recycling ecosystem. Policymakers have a unique opportunity to learn from the strengths of both technologies and create regulations that accelerate sustainability without compromising industrial growth. After all, the future of energy storage will not belong to a single battery chemistry. Different applications require different technologies, and each plays an important role in India's journey toward a cleaner and more sustainable future. SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connected Join my network on LinkedIn to engage on social media View my videos on my Youtube Channel to get further insights of Lead Acid Batteries

July 8, 202610 min

83. A Case Study – Positive Grid Corrosion

In this episode of my podcast, I share a real-life case study from a recent visit to the automotive battery industry. A manufacturer was experiencing many warranty claims due to positive grid corrosion. To solve it, they strengthened the grid by adding extra horizontal and vertical wires. The corrosion issue improved—but a new set of problems emerged. Battery capacity reduced OEM customers were unhappy with the heavier battery Assembly processes had to be modified Recharge time became longer One solution had triggered a chain of unintended consequences. When we stepped back and investigated the problem scientifically, we discovered that the real issue wasn't the grid design at all. The original corrosion problem was resolved—without redesigning the battery. This experience reinforced a lesson that applies far beyond batteries: Never treat the symptom before understanding the cause. In engineering, and in life, solving one visible problem without identifying its root cause often creates several new ones. A systematic, holistic approach almost always leads to a simpler, more effective, and more economical solution. I hope this episode provides useful insights for professionals in battery manufacturing, quality, R&D, and process engineering. I'd love to hear your thoughts: Have you ever seen a "solution" create more problems than the original issue? SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connected Join my network on LinkedIn to engage on social media View my videos on my Youtube Channel to get further insights of Lead Acid Batteries

January 1, 202625 min

82. The Write Inheritance: How Words Build Legacies

In this inspiring episode of The Write Inheritance, industrial marketer Bejoy Peter sits down with Ramesh Natarajan, well-known author and battery industry expert to explore the powerful connection between writing, influence, and legacy. From factory floors to life as a best-selling author, Ramesh shares how his journey through the world of batteries sparked stories that charge minds and move hearts. Together, Bejoy and Ramesh unpack the creative process, the discipline of writing amidst demanding careers, and why every professional - no matter their field - has a story worth telling. Expect witty insights, honest reflections, and a few “aha” moments that will make you rethink what your words can leave behind. Because in the end, ideas fade but what you write, lives on. SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connected Join my network on LinkedIn to engage on social media View my videos on my Youtube Channel to get further insights of Lead Acid Batteries

October 30, 20257 min

81. Stop Losing Power: The Connection Mistake Most Forklift Users Make

“Bolt it, or burn it?” That’s the question I explored in my latest podcast episode. Both bolt-on and weld-on cell traction batteries have their pros and cons — but the real difference shows up in: How they’re serviced, How they’re maintained, and How long they last. Most people think bolt-on cells are “better and convenient,” but do they realize the equalization step can make or break the battery’s life? Listen in as I explain why ease of service doesn’t always mean better performance. SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connected Join my network on LinkedIn to engage on social media View my videos on my Youtube Channel to get further insights of Lead Acid Batteries

September 18, 202517 min

80. 11 Guidelines for Success in the Battery Industry

🔋 What does it *really* take to succeed in battery manufacturing? It’s not just about chemistry and machinery. In my latest podcast episode, I discuss 11 powerful (and often overlooked) guidelines that separate thriving battery businesses from the ones that quietly disappear. This isn’t your typical technical talk — it’s about the real challenges, the silent killers of profitability, and the strategic decisions that matter most. Whether you're a manufacturer, entrepreneur, or industry enthusiast, this episode will give you insights you won't find in textbooks. I'd love to hear your thoughts after listening. ⚡ Let’s spark a conversation. #BatteryIndustry #ManufacturingLeadership #Podcast #BusinessStrategy #BatteryManufacturing #IndustrialInsights #Entrepreneurship SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connected Join my network on LinkedIn to engage on social media View my videos on my Youtube Channel to get further insights of Lead Acid Batteries

June 8, 20255 min

79. Bubbles on pasted plates – Why? A case study.

Bubbles on Pasted Plates… but why? Everything looked normal. •Same paste formula. •Same raw materials. •Same paste chemical additives •Same machine settings. But over 50% of the plates were getting rejected. Right after pasting. Before even reaching the drying oven. The QC team tried everything—tweaking the mix, rechecking materials, and recalibrating equipment. Still, the problem persisted. 👉 Then came a phone call. And a video. 🔍 What followed was a surprising discovery 🎧 In this case study, I walk you through a puzzling situation from a battery factory floor where logic, observation, and fresh eyes led to a surprising yet straightforward fix. To hear an engaging narrative, please tune in to this episode of my podcast. SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connected Join my network on LinkedIn to engage on social media View my videos on my Youtube Channel to get further insights of Lead Acid Batteries

May 28, 20257 min

78. Deep Discharge Of Lead-Acid Batteries Explained

Battery manufacturers specify the end-of-discharge voltage based on battery design and application. Any discharge below the end of the discharge voltage is termed a deep discharge. Deep discharges, especially when more frequent, lead to battery capacity loss and degradation of the active material. Batteries subjected to deep discharges fail prematurely. In the case of lead-acid batteries, deep discharges damage both the positive and negative electrodes. Sporadic and infrequent low voltages for a short period caused by a high current drawn from the load cannot be considered deep discharge. To understand the phenomenon of deep discharge, please tune in to this episode of my podcast, available on various streaming platforms. SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connected Join my network on LinkedIn to engage on social media View my videos on my Youtube Channel to get further insights of Lead Acid Batteries

May 25, 202531 min

77. Are EVs Fitted With Lithium-Ion Batteries The Future Of Passenger Transportation?

Electric vehicles, or EVs as they are more popularly known, are a sunrise sector with a lot of government encouragement so that car buyers shift to EVs from Internal Combustion Engine vehicles. Internal Combustion Engine vehicles are referred to as ICE vehicles. EV buyers are lured by the fuel cost savings that will accrue to them when they buy an EV. However, any fuel cost savings accrued to an EV owner have to cover the higher cost of EVs compared to ICE vehicles, insurance premium riders, high and probable maintenance expenses, battery replacement cost, roadside assistance charges, and the extra cost of towing the car. Regarding Total Cost of Ownership, the savings accrued after these expenses are covered can be considered real savings. Operational savings accrued every month are, at best, an eyewash. This podcast episode also dwells upon other issues, such as battery recycling and vehicle resale costs. Another unmissable episode for all EV users, dealers, and battery manufacturers. To hear this enlightening episode, please tune in to this episode of my podcast. SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connected Join my network on LinkedIn to engage on social media View my videos on my Youtube Channel to get further insights of Lead Acid Batteries

May 24, 20259 min

76. Lithium-Ion Battery Room Design Recommendations

Did you know that Lithium-Ion batteries are not similar to lead-acid batteries in terms of safety and handling procedures? The popularity of lithium-ion batteries has resulted in the spawning of many dealers, traders, and assemblers of cells and modules. This is a good development, but many entrepreneurs are unaware of the risks associated with lithium-ion batteries. Hence, I considered doing this podcast episode focusing on the facilities to be incorporated in the battery rooms, keeping safety in mind. I have touched upon the main aspects to consider when designing a battery room, and I hope this list is as comprehensive as possible. Lead acid battery manufacturers and dealers must listen to this episode. To hear this informative episode, please tune in to this episode of my podcast. SHARE YOUR FEEDBACK Visit, www.RameshNatarajan.in to stay connected Join my network on LinkedIn to engage on social media View my videos on my Youtube Channel to get further insights of Lead Acid Batteries

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