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India's Premier Battery Consultancy — Est. 2020

End-to-End Lead Acid Battery Engineering Solutions

A team of highly skilled engineers and technologists from Battery Research & Manufacturing — delivering technologically viable, economically affordable solutions globally.

🏭

Greenfield Plant Setup

Turnkey factory setup including equipment commissioning and full process support.

🔬

R&D & Process Audit

In-depth audits with corrective action plans from IIT-trained experts.

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Design & Compliance

Cost-effective best-in-class product design for all Vented and VRLA battery ranges.

2020
Founded
6+
Expert Consultants
35+
Avg. Years Experience
10+
Battery Types
Global
Client Reach
About BEC

Our Aim & Commitment

Battery Engineers Consultancy is formed as an association of experienced engineers and technologists from Battery Research and Manufacturing.

We provide complete end-to-end support for manufacture, design & process (including Lead Smelting and Lead Refining) for all kinds of Lead Acid Battery. We assist clients to select the most suitable design and process for their specific application.

Customer Satisfaction — always our top priority
Easy understandability of processes for client teams
Flexibility of Process and Design solutions
Solutions and actions aligned with Client's business interests
Technically and scientifically sound, target-oriented results

Vented / Flooded Battery Applications

  • Automotive Battery
  • E-Rickshaw Battery
  • Inverter Battery
  • Solar Battery
  • OPzS and Traction Battery

VRLA / SMF Battery Applications

  • Car Battery VRLA & Motor Cycle VRLA
  • UPS VRLA, 2V AGM VRLA, 2V GEL VRLA
  • 2V AGM GEL VRLA, 12V Inverter AGM GEL VRLA
  • OPzV Battery, E-Scooter Battery
  • Two Wheeler VRLA Battery, 2 Volt VRLA

Range of Services

  • Turnkey Factory Setup & Commissioning
  • Lead Smelting & Refining Project Setup
  • TPM / Lean Manufacturing Implementation
  • Train the Trainers & Leadership Programme
  • Selection & Recruitment of Manufacturing Team
Our Work in Action

Battery Engineering Gallery

What We Do

Core Services

BEC provides complete end-to-end engineering support — from design to commissioning — for the global battery industry.

01
🏭

Greenfield Plant Setup

Turnkey battery factory setup including commissioning, equipment selection, and complete process design support.

02
⚙️

Lead Smelting & Refining

Turnkey project setup of Lead Smelting and Refining, including designing and manufacturing of specialised equipment.

03
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Process & Product Audit

In-depth audits of manufacturing units for all battery types, with corrective action plans to improve quality and efficiency.

04
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TPM / Lean Manufacturing

Setup and implementation of TPM, Lean Manufacturing, and customised improvement systems for operational excellence.

05
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Training Programmes

Train the Trainers and Executive Leadership Programmes to build technical capability within your manufacturing teams.

06
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Talent & Recruitment

Selection and recruitment of experienced manufacturing teams for new battery plants and expansion projects.

Areas of Expertise

Battery Application Types

Automotive

Inverter

Traction

E-Rickshaw

Gel Tubular

OPzS & OPzV

UPS VRLA

E-Scooter

Two Wheeler

2 Volt VRLA

Meet Our Experts

Expert Consultant Team

Decades of senior leadership from India's top battery manufacturers — Exide, Tudor, Okaya, Minda, Base Corporation, and more.

CG

Mr. Chittaranjan Ghosh

Chief Technical Advisor
  • Head of Technical Dept — Exide Industries Ltd (till 2000)
  • Technical Advisor — Abtab Automobile Bangladesh
  • General Manager — Luminous
  • Director — Okaya Group & Eastman Auto
  • Owner of US Patent No. 11145855
SS

Mr. Subhashish Sen

Managing Director
  • Section Manager — Exide Industries Ltd (multiple units)
  • Head of Projects — Tudor India Ltd (Exide USA)
  • Plant Head — Base Corporation
  • DGM — Minda Industries
  • CEO — Jay Ace Battery
DM

Dr. Debashish Mazumdar

R&D Expert, Power Dynamics
  • Doctorate from IIT Kharagpur
  • 37 Years total experience in battery R&D
  • Executive Vice President (R&D) — Exide Industries Ltd
  • Retired 2020, now active in consultancy
AR

Mr. Alwyn Rodrigues

Senior Consultant
  • Kalyani Steels / Chloride India / Standard Furukawa
  • GM Operations — Exide Industries (Taloja)
  • Vice President — Minda Industries
  • Sr. Vice President — Base Corporation
  • Sr. Consultant — Pilot Industries / Tudor India
VS

Mr. Viswanathan Sankaran

Technical Consultant
  • CECRI / AES Chemicals / Titan Solar Energy Systems
  • Technical Manager — Standard Furukawa
  • GM Technical — Nife Power Systems
  • GM QA R&D — Union Batteries / Base Corporation
Client Testimonials

What Our Clients Say

"

Subhashish is an experienced Battery Production and Planning professional who has kept abreast with times. His knowledge of machinery and technology in Battery Production is indeed commendable.

SS
Mr. Sachin Sridhar
Founder, Starlit Group
"

Subhashish has solid technological strength and team leading skills. He has extremely sound knowledge of Lead Acid Battery Technology, particularly in VRLA Battery Technology.

RJ
Mr. Ranjit Jakkli
Managing Director, Kraft Powercorn
"

A fine professional with excellent knowledge on all aspects of Battery manufacturing. His rich experience coupled with man management skills makes him an asset for any organization.

AM
Mr. Anil S Makhloga
CEO, Greaves Cotton Limited
"

We are very happy to work with Battery Engineers Consultancy from India. We appreciate their productive approach regarding Machines, Development of Design and Process of Inverter Battery.

HS
Mr. Haytham Shalabi
MD, Gammar Battery, Sudan
How We Work

Our Process

A structured engagement model to deliver consistent results for every client project.

01

Initial Enquiry

Client shares requirements — new plant, expansion, or improvement — and we assess feasibility.

02

Technical Scoping

Our experts define the design, process parameters, and cost-effective solution strategy.

03

On-Site Execution

Consultants deploy on-site for plant setup, audits, training, or manufacturing support.

04

Ongoing Support

Post-deployment monitoring, R&D liaison, and continued technical guidance as needed.

Get in Touch

Have an Idea?
We'll Make It Happen.

BEC is a one-stop solution. Our technical team provides end-to-end design support for all ranges of Vented and VRLA Lead Acid Battery, including Greenfield and Capacity Expansion projects.

📞
Phone
+91 88004 70937  /  +91 90733 89997
🌐
Website
batteryengineersconsultancy.co.in
🇮🇳
Registered
India — Serving Global Clients

Work Policy

Turning Knowledge into Power for our Customers & Partners

Policy Summary

Our Work Standards

Our work policy ensures that every client receives structured, traceable and cost-effective engineering solutions backed by proven industrial expertise.

Policy Highlights

  • Custom crafted Battery Test Structure for Production Line Quality Assurance
  • Easy to use operator interface
  • Improved product traceability and accounting
  • Increased operational orderliness and lowered cost of Quality Assurance
  • Extensible solution to adapt to future demands

Previous Endeavors

  • Process Audit of manufacturing units: conventional LA, AGM VRLA, Gel Tubular, Automotive, Invertor, Traction, Solar, OPzS & OPzV, E-Vehicles
  • Greenfield battery projects: Conventional LA, Invertor, AGM VRLA, Gel Tubular, Traction
  • Validation Process of Battery Design for cost-effective solutions
  • Capacity Expansion with introduction of new technology (Gel Tubular, AGM VRLA)
Battery manufacturing

Industry Growth — Lead Acid Batteries

Lead Acid batteries can be deemed a 20th century ecological success story. Over 97% of battery lead is recycled — compared to 57% for aluminium cans and 26% for glass bottles. About 60–80% of new batteries are made from recycled lead and plastic, creating a near-perfect closed-loop lifecycle. The industry is entering unprecedented expansion driven by government emissions policies and improving battery performance-to-cost ratios.

Work Philosophy

"A Dream doesn't become reality through magic. It takes sweat, determination and hard work."

Our Philosophy

How We Think & Work

Our business policy revolves around providing deliverables and solutions that meet client expectations. We at BEC have worked with companies varying in size from major Multinational Establishments to blooming start-ups. Our approach to all our customers remains the same — to provide a professional and cost-effective solution to the posed problem in a timely manner.

Our service can help you understand the market demands in India and worldwide. We hope you find the information on our platform fruitful and we are pleased to answer any question you might have.

🤝 Client First

Every engagement begins and ends with client satisfaction and business success as the primary goal.

⚡ Timely Delivery

We ensure solutions are delivered on schedule without compromising on technical quality or safety.

💡 Innovation

Continuously updating our knowledge of new technology developments to provide the most current solutions.

🌍 Global Perspective

We bring international market insight to every Indian and global client engagement.

Team philosophy

Our Commitment to You

Whether you are a major multinational or a start-up entering the battery market, BEC brings the same level of rigour, professionalism, and commitment to every project. We believe that knowledge, applied with dedication, is the most powerful tool in engineering.

Quality Policy

Our primary goal is to deliver extraordinary quality work to every client.

Quality Assurance

Our Quality Commitment

We promise complete customer satisfaction and fulfillment of the goal. Quality Assurance is our forte and our excellence is derived from years of hands-on industrial experience.

Quality Excellence is Derived From:

  • Many years of versatile Industrial Experience in Battery Technology
  • A wide international network of expertise in the battery and storage industry
  • A continual desire to understand and expand skill sets on new developments in Technology and Science for upgrading Battery Manufacturing Process

Our Interdisciplinary Team

We are proud to have an interdisciplinary team of professionals with considerable expertise in batteries, battery components, and energy storage technology. With this cumulative experience, we work to develop the most effective and profitable solution for your establishment to achieve long-term organisational success.

Quality control

✅ Vented Battery

Automotive, E-Rickshaw, Invertor, Solar Application

✅ VRLA / SMF Battery

4 Wheeler VRLA, 2 Wheeler VRLA, UPS VRLA

Mr. Chittaranjan Ghosh

Chief Technical Advisor — Battery Engineers Consultancy

👨‍🔬
Key Achievement
🏆 US Patent No. 11145855
Battery Technology Innovation

Mr. Chittaranjan Ghosh

Chief Technical Advisor

Mr. Chittaranjan Ghosh is one of India's foremost authorities in Lead Acid Battery technology. With decades of leadership in India's top battery manufacturers, he has steered technical departments through transitions in technology, process, and product design. Since 2012, he has channelled this expertise into independent consultancy, culminating in a US Patent for battery technology innovation.

Career Timeline
Head of Technical Department — Exide Industries Limited (till 2000)
2001–2002: Technical Advisor — Abtab Automobile Bangladesh
2003: General Manager — Luminous
2004–2007: Director — Okaya Group
2008: Director — Eastman Auto
2009–2011: Director — Deepak Power Storage Enterprise
Since 2012: Independent Consultancy & Research — Owner of US Patent No. 11145855

Mr. Subhashish Sen

Managing Director — Battery Engineers Consultancy

👨‍💼

Mr. Subhashish Sen

Managing Director

Mr. Subhashish Sen is the Managing Director of Battery Engineers Consultancy. A highly seasoned battery manufacturing professional with leadership experience across India's top battery companies, he has held senior roles spanning production, projects, and executive management. His expertise spans the full lifecycle of Lead Acid Battery manufacturing from cell chemistry to plant-level operations.

Career History
Section Manager — Exide Industries Limited (Haldia, Chinchwad, Shamnagar & Hosur Units)
Head of Project and Maintenance — Tudor India Ltd (Indian arm of Exide USA)
Plant Head — Base Corporation
DGM — Minda Industries
General Manager — Panna Battery, Dhaka
General Manager — Base Corporation & Okaya Power
CEO — Jay Ace Battery

Dr. Debashish Mazumdar

Nominated R&D Expert from Power Dynamics Consultants

🎓
Credentials
🎓 Doctorate — IIT Kharagpur
🔬 37 Years R&D Experience
🏭 EVP-R&D, Exide Industries
💼 Annual Turnover: ~INR 12K Cr

Dr. Debashish Mazumdar

R&D Expert — Nominated by Power Dynamics Consultants

Dr. Debashish Mazumdar holds a Doctorate from IIT Kharagpur and brings 37 years of hands-on experience in design and development at Exide Industries Limited — India's leading Lead Acid Battery manufacturer with an annual turnover of approximately INR 12,000 crores (1.5 billion USD). He retired as Executive Vice President (EVP-R&D) in May 2020 and has since been actively engaged in consultancy services through Power Dynamics Consultants, which nominated him as the key R&D resource for BEC.

Last Designation: Executive Vice President (EVP) — R&D, Exide Industries Limited
Total Experience: 37 years (including 2 years post-retirement consultancy)
Introduced complete PP SLI car battery range and extended to LCV, Jeep, HCV, Tractor segments
Introduced Maintenance Free flooded battery for the first time in India for the entire Automotive range
Developed products for Defence applications including Tank, signalling and armoured vehicles
Led ISO 9000/QS-9000/TS certification and introduced APQP, PPAP, DFMEA/PFMEA, TS 16949

Mr. Alwyn Rodrigues

Senior Consultant — Battery Engineers Consultancy

👨‍🏭

Mr. Alwyn Rodrigues

Senior Consultant

Mr. Alwyn Rodrigues brings exceptional depth in battery manufacturing operations and senior leadership, spanning from technical roles early in his career to Vice President and Sr. Vice President level at some of India's leading battery organisations. His experience encompasses operations, quality, and strategic plant management.

Kalyani Steels / Chloride India / Standard Furukawa
Exide Industries — Chinchwad
GM Operations — Exide Industries, Taloja
Vice President & UBH — Minda Industries
Sr. Vice President — Base Corporation
Sr. Consultant — Pilot Industries / Tudor India

Mr. Viswanathan Sankaran

Technical Consultant — Battery Engineers Consultancy

⚗️

Mr. Viswanathan Sankaran

Technical Consultant

Mr. Viswanathan Sankaran is a seasoned battery technologist with deep expertise in technical management and Quality Assurance & R&D, spanning from electrochemistry research institutions to senior GM-level roles in India's battery industry.

CECRI (Central Electrochemical Research Institute)
AES Chemicals / Titan Solar Energy Systems
Ghannami Chloride
Technical Manager — Standard Furukawa
GM Technical — Nife Power Systems
GM QA R&D — Union Batteries / Base Corporation

Mr. Siddhartha Das

Quality & Technical Expert — Battery Engineers Consultancy

🔧

Mr. Siddhartha Das

Quality & Technical Expert

Mr. Siddhartha Das brings over 35 years of hands-on technical and quality expertise from Exide Industries, India's most respected Lead Acid Battery manufacturer. He has managed large-scale cross-cultural teams and driven new technology implementations to improve production quality and efficiency across multiple business lines.

Last assignment: DGM Technical — Deepak International
35+ years at Exide Industries Limited — Quality/Technical Head, Exide Shamnagar (West Bengal)
Led cross-cultural manpower of 1,100 workers and 25+ staff across multiple business lines
Experienced in implementing new technologies to improve production processes and upgrade product quality
Skilled in enhancing quality, improving operational efficiency, process effectiveness, and achieving cost reduction

Battery Technical Service

Our Modus Operandi — End-to-end engineering support powered by decades of industry expertise.

Modus Operandi

How We Deliver

Our Technical Approach

  • Foundation of Electrochemical Engineering and Material Science
  • Innovative cost-effective design from our experienced R&D Team, complying with international manufacturing protocols
  • Guiding the technical team at client site about the latest technology
  • Constant support to integrate technologically advanced and economically viable solutions, as well as energy conservation
  • Installation and commissioning of Machines
  • Spearheading complete project operations, including accountability and provision of business solutions
  • Turnkey Project of Lead Smelting and Lead Refining
Battery technical service
Areas of Expertise

Battery Application Expertise

Automotive

Inverter

Traction

E-Rickshaw

Gel Tubular

OPzS & OPzV

UPS VRLA

E-Scooter

Two Wheeler

2 Volt VRLA

Have an Idea? We Will Make It Happen!

BEC is a one-stop solution provider. Our technical team is highly experienced in delivering engineering support, offering end-to-end design services such as the setup of Lead Smelting and Lead Refining projects for manufacturing customized products — (1) all ranges of vented lead-acid batteries, and (2) all ranges of VRLA/SMF lead-acid batteries.

We have strong expertise in executing both greenfield and capacity expansion projects. Our R&D team closely monitors processes, design, and laboratory testing, while also conducting audits of operating plants. In addition, we provide training and knowledge-sharing sessions for Quality and R&D teams at client sites.

Power Dynamics Consultants

Strategic R&D partner to Battery Engineers Consultancy

👩‍🔬
Founded
📅 14 March 2021
📍 Kharghar, Panvel, Raigad, Maharashtra
🔬 Battery Consultancy + Drug Design R&D
About Power Dynamics

Dr. Suchismita Mazumdar

Power Dynamics Consultants was founded by Dr. Suchismita Mazumdar on 14 March 2021 (Registered Office: Kharghar, Panvel, Raigad, PIN – 410210, Maharashtra). She holds a Doctorate Degree in "Biotechnology and Bio Informatics" and has more than 15 years of experience in SAP modules. She is currently actively involved in Drug Design for Cancer and Diabetes.

Her latest venture is in Battery Consultancy, in which she has already provided time-bound consultancy in Greenfield Projects. Power Dynamics has nominated Dr. Debashish Mazumdar (Doctorate from IIT Kharagpur) for the R&D division of Battery Engineers Consultancy, bringing 35 years of experience at Exide Industries Limited.

Dr. Debashish Mazumdar — Key Achievements at Exide
PP Battery RangeIntroduced complete Polypropylene SLI car battery range, extended to entire SLI segments.
MF BatteryIntroduced Maintenance Free flooded battery for the entire Automotive range for the first time in India.
Defence ProductsDeveloped products for defence: Tank, signalling, and armoured vehicle batteries.
VRLA MotorcycleIntroduced punched plate technology in VRLA Motorcycle battery — first in India.
EFB & ISS BatteriesIntroduced Enhanced Flooded Battery (EFB) and ISS batteries in JIS and DIN range in OE and aftermarket segments.
E-Rickshaw BatteryIntroduced high-life E-Rickshaw battery with higher and consistent mileage and very low water loss.
OEM Quality AwardsLed team to receive prestigious quality awards from MSIL, HONDA, Hero Motors, VW, Tata, Mahindra, Bajaj Auto.
Pulse ChargingIntroduced special pulse charging and Jar formation technologies reducing power cost and enhancing output.

Frequently Asked Questions

Technical queries from our Battery manufacturing friends — answered by our expert team.

Manufacturing Issues

Common Battery Problems

Real-world problems raised by battery manufacturers, with root cause analysis and solutions from our expert consultants.

Sticking in Pasted Plates
Causes:
  1. Acid wash not done after pasting
  2. Higher moisture content paste used
  3. Low flash drying oven temperature
  4. Plates stacked tightly in racks
Variation of Pasted Plate Weight
Causes:
  1. Variation in Grid Panel weight
  2. Variation in Paste Density than specification
  3. Improper condition of Pasting Hopper
  4. Improper condition of Pasting Machine
  5. Pasting Machine setting problem
Flash in Grids
Causes:
  1. Lead alloy composition not ok
  2. Improper Mould Temperature
  3. Poor cork powder spray on mould
  4. Improper surface of Grid Mould due to age
  5. Mould closing mechanism is not proper
Crack in Grids
Causes:
  1. Lead alloy composition not ok
  2. Improper Mould Temperature
  3. Mould water cooling path choked
  4. Improper Mould spraying
  5. Mould Air venting is not proper
  6. Machine speed higher than standard
Battery Burst
Causes:
  1. Internal Spark
  2. Higher Gas Generation
  3. Vent path choked
  4. Gassing Space not maintained
  5. Material and Process of Plastic Moulding
Positive / Negative Plate Paste Shedding
Causes/Solutions:
  1. Improper paste Density
  2. Improper curing of plates
  3. Loose Cell fitment
  4. Improper Side packing
  5. Design of Pasting Hopper
High Water Loss
Causes:
  1. High Antimony percentage in Lead Alloy for grid casting
  2. Design the battery to accommodate more acid on top of the plates
  3. Over charging of Battery
More Issues
One Cell Gravity Low
Causes:
  1. Poor inter cell welding
  2. Poor group burning
  3. Active material shedding
  4. Iron & Chloride contamination
  5. Micro Short
Cell Short
Causes:
  1. Lead Run during Group Burning
  2. Lead Run During Pole Burning
  3. PE-Separator misalignment
  4. PE-Separator Puncher
  5. Improper cleaning of Paste on Lug and Plate's side
  6. Separator Height overlapping by 8 to 10 mm
Pole Melt
Causes:
  1. Loose wire Connection
  2. Improper Pole Burning
  3. Highly Oxidised
  4. Pole crack
  5. Terminal crack
Battery Acid Leakage
Causes:
  1. Lid & container Sealing joint not ok
  2. Grade of PPCP Material is not proper
  3. Mishandling
  4. Acid level is not maintained
  5. Vent Plug design is not proper
Low Backup / HRD Fail
Causes:
  1. PAM/NAM Softening
  2. Hard Sulfation formed during plate making process
  3. Positive/Negative paste Degradation
  4. Improper Charging Inputs
  5. Weak intercell welding
Cracking of Strap and Pole
Causes:
  1. Lead pot alloy composition not ok
  2. Improper controlling of Lead pot temperature
  3. Strap and pole part cooling not ok
  4. Overage strap and pole parts used
  5. Mishandling during burning process
  6. Bad condition of Mould
Paste Shedding from Cured Plates
Causes:
  1. Curing reaction not properly done
  2. Paste to grid bonding not done
  3. Curing program not ok
  4. Paste moisture was not maintained
  5. Free Lead conversion is not proper
🤔
Have a different question?
Our experts are ready to help with any battery manufacturing challenge.

Get In Touch

Have an idea? We will make it happen. Talk to our expert team today.

Contact Details

Reach BEC Experts

BEC is a one-stop solution. Tell us about your battery engineering challenge and our team will respond within one business day.

📞
Phone
+91 88004 70937  /  +91 90733 89997
🌐
Website
batteryengineersconsultancy.co.in
🇮🇳
Base
India — Serving Global Clients
SERVICES WE CONSULT ON
Plant Setup Lead Smelting Process Audit TPM / Lean Training VRLA Design Recruitment
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