HBL Power Systems Ltd

The company manufactures specialised batteries and offers solutions for specialised applications

From the tiny pacemakers used to control the rhythm of the heart with a problem to the complex International Space Station parked in the low earth orbit, batteries play a vital role in the functioning of all devices that need electric power to function continuously. A failure would lead to fatal consequences, a plain fact that sums up the importance of the humble battery, which like the devices it powers, comes in all sizes, from tiny titbits to massive units weighing several tonnes. Batteries also come in hundreds of types, based on various principles of operation.

Hyderabad-based HBL Power Systems is an organisation engaged in the design, development and manufacturing of specialised batteries, DC systems and other specialised products to the need of Indian industry. Its products cater to many different segments, addressing diverse needs, within the borders of the country and beyond. These include: industrial; telecom; railways; defence; aviation; automotive; and specialised projects & applications, etc.

Like most enterprises, the by now ISO 9001 & ISO 14001 certified company started operations in 1977 at Hyderabad on a modest scale and has grown over the years as a major manufacturer and exporter, with an annual turnover in excess of ` 1300 crore. "The vision of the company," explains T Venugopal, Vice President Lead Acid - Technology Group, "is to organise India's engineering talent into a globally competitive business, whether in manufacturing or in services. The choice is for businesses with technological barriers and/or engineering intensity. Our location at Hyderabad makes this vision feasible, because the city has India's largest cluster of scientific and technical training institutions providing high calibre human resources."

Operations & Customer Segmentation

With dedicated employee strength of around 3800, and a factory space exceeding 200,00 sq.m scattered in Hyderabad and other parts of the country, the company straddles across a range of batteries and related power products.

The complete product portfolio is described briefly in the following paragraphs.

A) Specialised Batteries

• Nickel Cadmium
• Lithium
• Silver Zinc, and
• Lead Acid, etc.

B) Electronics

• Railway Signalling Systems
• Defence Electronics, and
• Industrial Power Electronics, etc.

C) Batteries for Solar & Wind Energy, etc

The company manufactures a wide range of batteries to store energy generated through non-renewable energy sources like Solar and Wind Power:

• Tubular Gel Battery
• OPzS Battery
• OPzV Battery
• Triumph Solair series (VRLA-AGM) Battery
• Tubular Low Maintenance Lead Acid Battery, and
• Nickel Cadmium Battery.

Apart from this wide range of batteries, the company also manufactures Soleckshaw - a solar power assisted power Rickshaw, which displayed at the recently held SOLARCON INDIA 2010 expo organised in Hyderabad.

D) Batteries For Electric/Conventional 2-Wheelers

For electric vehicles, the company manufactures the EV/SLI range of batteries for 2-wheelers, which run with the traction motor, and rear wheel driven vehicles manufactured by Ultra Motors, New Delhi; and Eco Vehicles, Bangalore.

The range includes:

• G-Ride Batteries, and
• SLI - Batteries for 2- and 4-wheeler applications.

E) Batteries for Automotive/Engine Start (DG sets) - PLT SMF VRLA Batteries

The company has the expertise to make VRLA batteries (indigenously developed) for various industrial, telecom applications from 1984. With in-house R&D and experience in developing new technologies indigenously, it started working (from 1998) on engine starting batteries for main battle tanks and aircraft on-board starting. The result is a thin plate Pure Lead Tin (PLT) technology, whose main feature is very high surface area which results in high cranking ability even at very low temperatures, an essential parameter for defence applications. Pure lead tin alloy has less corrosion, which results in longer battery life.

• BR 100 - Battle Ready (12 V 100 Ah) Battery is approved for use on main battle tanks and it has NATO approved stock number, and
• Silver Start SS 28300 is approved by RCMA, Govt of India to use on MI 8, MI 17 and MI 35 helicopters.

The thin plate feature of the PLT battery enables to deliver more cranking current to the extent of 2.5 times for the same Ah rating of the conventional battery. HBL is the only manufacturer of these batteries in India and third company globally to do so. The company has now introduced batteries with PLT thin plate technology under "Ignite" brand for passenger cars (SUVs), heavy commercial vehicles (HCVs) and heavy earth moving machinery (HEMM).

The product range covers from IG 25 (12 V 25 Ah) to IG 160 (12 V 160 Ah) models, conforming to International Product Standards IEC 60095. The high cranking ability of the battery provides an advantage in using a smaller capacity of battery for the same application with less weight. For example: two 12 V 160 Ah Ignite batteries can replace four batteries of 12 V 180 Ah for use on an 85-tonne dumper equipment. The remarkable advantages of these batteries are: sealed maintenance free (SMF), long life, compact and smaller in size and weight, high charge retention capability and high cranking current (CCA). These batteries are already in use with the mining sector, OEMs/ Volvo replacement market, STUs - state transport undertakings, and passenger car segment, etc.

Engine Start Applications (Xcell) for DG Set

HBL Batteries with PLT technology also achieved a remarkable place in the DG set segment with its distinctive feature of built in SMPS battery charger which ensures optimum charging of the battery at all times and the DG set would be in "ever ready status" to meet the customer needs. The application range of Xcell PLPP (with built-in charger) range includes 15 kVA to 1500 kVA DG set start up battery package.

F) VRLA Products & Applications

The VRLA is a premium Valve Regulated Lead Acid battery, which works on gas recombination principle and has been designed to suit wide range of applications as mentioned below:

• 2 V Triumph HP: Range 80 Ah to 5800 Ah for telecom, power, railway, oil and gas, UPS application, etc
• 2 V Triumph BTS-R: Range 200 Ah to 600 Ah for telecom applications, etc, and
• 2 V Triumph Solaire: Range 250 Ah - 3000 Ah for Solar Wind stations, etc.

G) Tubular Gel VRLA Batteries

The most recent development at HBL is the Tubular Gel VRLA Battery, developed through in-house R&D.

Tubular gel VRLA technology, based on gas recombination principle, meets the international quality standards and is proven by rigorous laboratory and field tests. It is the ideal choice for applications in solar, telecommunications, railways and power segments.

The Tubular Gel VRLA range comprises:

a) 2 V single cells - 120 Ah to 1250Ah - higher capacities up to 5000Ah can be achieved by paralleling of basic cells, and b) 12 V monoblocs - 60 Ah to 180 Ah. Applications are in segments like: solar photovoltaic, telecommunications, railways, and power plants.

Major customers in various sectors are: 1. Telecom - BSNL, Indus Towers, Bharti Infratel, Reliance Communications, Idea, Vodafone, etc; 2. SPV - Moser-Baer, Tata-BP Solar, Bhutan Telecom, Indonesia Telecom and Alacatel - Turkey.

Exports & Global Presence

About 15% of total net sales of HBL are accounted by exports to Europe, USA, the Gulf, China, South East Asia and many other countries.

The company has been exporting NiCad passenger aircraft batteries to USA and the CIS countries, apart from other markets and ranks 3rd globally in this area. In industrial alkaline batteries, it has many prestigious customers and ranks 2nd globally.

Expositions - Seminars

HBL has a vibrant presence in the national and international conventions organised from time to time. The recently concluded 3rd International Battery Expo & Recycling Conference, IBRX INDIA - 2010, during March 3-5 at NOVOTEL Hotel Hyderabad - India was one such convention that witnessed participation of various countries. During this convention, Dr Pavlov of Bulgarian Academy of Sciences was among the distinguished guests, who visited HBL's stall and exchanged various technology related issues with Mr T Venugopal, Vice President Lead Acid -Technology Group.

Future Expansion

The company has drawn plans to expand into automotive SLI batteries for both 2- and 4-wheelers at a capacity of 3 million units each per annum by 2012 at the new location in Mahaboobnagar district in Andhra Pradesh. In addition, it is setting up a partnership plant in Saudi Arabia for tubular batteries and traction batteries. The company is also diversifying into solar panel manufacturing to cater to this sunrise industrial segment. All these expansions can take HBL turnover to ` 5000 crore by 2015.

Environmental Care & Concern

As a responsible corporate entity, HBL Power Systems has strong commitment to protect the environment hence all suitable precautions are taken in the manufacturing process. To handle the noble cause of environment protection, the company takes extra care and is equipped with the following facilities and certifications:

• OHSAS 18001 certified
• Full fledged effluent treatment plant waste and sewage
• Reverse osmosis plant to purify water
• Approved battery recycling plant
• Safety awards, and
• Energy saving award.

(Contact: Mr K Parthasarathi, Additional General Manager, MBD - Business Development, HBL Power Systems Ltd, Mahaboobnagar, AP. Tel: 08548-240456-65. Fax: 91-8548-240472, 240474. Mobile: 09440667222. Email: kps@hbl.in)