In order to meet rising global demand for start-stop batteries – part of the quest to reduce CO₂ emissions – the Power Controls business division of Johnson Controls (JCI, Milwaukee, Wisconsin / USA; www.johnsoncontrols.com) has announced plans to lift output of the required lead nonwoven chargers – also known as absorbent glass mat (AGM) batteries. The latter are considered to be the technical core of start-stop systems thanks to their ability to supply the vehicle’s electric systems that come to play when the engine is switched off.

JCI estimates that the current market volume for these types of batteries stands at about 22m units for both new vehicles and spare parts. By 2020 the world’s largest producer expects output to reach 56m batteries. By that point, 85% of all new vehicles in Europe and 40% of those on the US and China will be equipped with start-stop batteries. The housings will consist mostly of polypropylene, with each battery taking up between 1.5-8 kg of the plastic. The batteries also contain separator films that consist of polyolefins.

Johnson Controls did not disclose the investment sum for the expansion plans and the new facilities. However, from 2011-2020 the entire division plans to invest USD 555m. Some of that money went towards an expansion of the company’s plants in Hanover and Zwickau, both in Germany. The plans also include a capacity expansion at the facility in Toledo, Ohio / USA, as well as the construction of an entirely new USD 200m battery plant in Shenyang, Liaoning province / China, due to start up by 2018. "By 2020 China will become the world’s largest market for vehicle batteries," says Johnson Controls Power Solutions president Joe Walicki.

In addition, Johnson Controls recently signed a declaration of intent with Beijing Hainachuan Automotive Parts (BHAP) for a joint venture for the sale and manufacture of vehicle batteries. BHAP is a division of automotive builder Beijing Automotive Industry Group (BAIC), one of China’s larger OEMs.