Inside the AGM battery

There is plenty of excitement about AGM batteries in the golf and electric car industry. I thought it would be helpful to find an expert and get the inside story, so I spoke with Christine Johnson with Fullriver Battery Group. She is a degreed Engineer, with an MBA from Pepperdine University. Ms. Johnson was with Trojan Battery for
12 years. Her first 5 years as an engineer and her last 7 in sales and marketing before coming on board with the team at Fullriver Battery Group.

Briefly tell us what an AGM battery is?

AGM batteries are sealed lead-acid batteries, similar to traditional wet lead-acid batteries however the electrolyte/acid is absorbed in a fiberglass material. Another difference is that AGM batteries are sealed, so that the gasses produced during operation remain within the battery rather than being released. The sealed construction means there is no water loss in AGM batteries.

What makes the AGM superior to the traditional Deep Cycle lead acid battery?

The main advantages are that they are; non-spillable, non-hazardous and maintenance-free. AGM batteries eliminate labor time and ultimately, the cost and inconvenience associated with watering batteries and corrosive acid residue clean up and replacement of corroded cables and connections. AGM batteries are safer since they rarely emit gasses. They have lower internal resistance allowing them to be charged faster than traditional wet deep cycle batteries. Finally, a properly designed AGM battery will give more range/runtime in the same size case as a traditional wet lead-acid battery. We hear about improved shelf life or storage life of AGM batteries.

Can you explain how that works and what the advantages are for dealers and consumers?

All lead-acid batteries self discharge, however the alloys typically used in AGM batteries reduce the amount of self discharge significantly. Less self discharge equals longer shelf life, which means AGM batteries can be stored during off seasons, without needing a boost charge, unlike traditional wet batteries that need frequent boost charges to avoid sulfating. Less self discharge also makes AGM batteries less prone to freezing since wet batteries can freeze when the specific gravity of the acid gets too low. A traditional wet battery can discharge between 9-12% per month, whereas an AGM battery will only discharge 1-3% per month – that is a significant difference.

What applications are AGM’s best suited for?

AGM deep cycle batteries that are designed properly can be used anywhere a traditional wet deep cycle lead-acid battery is used. They are best suited for applications in which the vehicle owner is trying to reduce downtime often due to unmaintained wet batteries and ultimately reduce overall maintenance costs. They are also ideal in vehicles used indoors or in proximity to people such as in hospitals, airports and schools, since they are non-spillable and non-hazardous.

Is the warranty or reliability better?

Warranty and reliability vary by manufacturer. Fullriver Battery stands behind its product and offers a warranty comparable to or better than other reputable traditional wet deep cycle battery manufacturers.

Why is the cost so high?

The cost is higher for AGM batteries compared to traditional wet lead-acid batteries due to the purity of materials required to make good AGM batteries as well as the cost of the manufacturing process.
It’s as simple as that.

What should a dealer consider to justify the increased cost against the benefits?

As illustrated below, both time and safety will play a factor. Maintenance cost and lack of proper maintenance can add hidden cost to the overall bottom line cost of a battery system.

Comparison of the cost of Fullriver
AGM batteries to traditional wet batteries

• Maintenance Costs
Wet batteries often need to be watered every 2-4 weeks depending on usage. Each cell needs water so if you have a 48 Volt system you will have 24 cells to water. If you have a fleet of 50 golf cars you would have to water 1200 cells. Not only do you have a big job to do, but you have to do it perfectly. Even one incident of over- or under- watering your wet battery can significantly reduce its capacity and life.

• Cable Replacement and Damage Repair Costs
Wet batteries release acid mist onto the top of the batteries and the environment. This acid residue not only corrodes the battery terminals, which can lead to loose connections and ultimately terminal melting, but can also corrode the battery compartment, vehicle chassis and even the floor. Without regularly cleaning the connections and the battery compartment, the cables will eventually need replacing and there may be very high damage repair costs.

• Battery Replacement Costs
Unless wet batteries are maintained perfectly, they will often fail prematurely and need replacing long before a Fullriver AGM battery.

What makes your Fullriver AGM battery superior to others in the market?

First and foremost Fullriver has designed its batteries to have all the features of a true deep cycle battery. Fullriver goes beyond the basics and added design features, such as over-the-partition cell-to- cell welding, which makes its batteries even more robust to withstand shock and vibration. Most manufacturers do not add in these extra features leaving a weak spot for potential failure. With such a solid design Fullriver will only use the highest quality components and raw materials available. Finally there is the manufacturing process; again Fullriver does not cut corners. There are many processes such as plate pasting and curing times that can make the difference between just a battery and a top performing battery. Fullriver Battery specializes in manufacturing only sealed, maintenance-free AGM batteries. Many manufacturers of traditional wet batteries do not actually produce their AGM batteries but rather source from another manufacturer. And these manufacturers make private labeled products for a number of battery manufacturers including themselves. Fullriver Battery manufactures its own batteries from grid casting through final assembly. This means the entire manufacturing process is controlled within the Fullriver factory to ensure batteries adhere to the engineering specifications. It also ensures consistency in product quality and performance, which is of utmost importance to Fullriver Battery.

As a manufacturer of the AGM what growth do you see in AGM sales over traditional lead acid?

AGM batteries have been well received in the floor care industry and other commercial applications. Once golf car customers experience the benefits of AGM batteries they will be hard pressed to go back to the traditional wet lead acid batteries