dailydriver, I appreciate your questions. While there was some crossover between the two production facilities, it is generally safe to say that batteries produced before 2008 were built in Aurora. The bottom line is that we didn't build a brand-new, state-of-the-art facility to cut corners, we did it to make a better product. That facility was built using Six Sigma methodology and is ISO 14000 certified for environmental management and ISO/TS 16949 for quality management.
Unlike brands that use third-party manufacturers to produce products to their specifications, we own this factory and the people who work there are our employees. Our parent corporation, Johnson Controls, is very conservative in their approach to business and fully-understands Optima's position as the leader in the automotive AGM aftermarket. I've read varous theories and I understand that personal experiences can vary, but the quality of our products has never been better.
It does cost more money to use pure lead, which is why so many other AGM products are moving to recycled lead. It doesn't perform as well or last as long as pure lead, but it is still better than a flooded battery (which also probably uses recycled lead). At the risk of sounding like a battery nerd, our grid alloy is one of the most corrosion-resistant alloys in production. The high purity of the alloy and it's simple, binary composition also minimizes gas generation. Typical wet or flat-plate AGM batteries use grid alloys that contain three or four elements, which results in lower overall purity and gassing characteristics that are not as good as Optima's binary lead alloy. As a result, Optima batteries will have less corrosion at elevated temperatures and less water loss, when compared to conventional wet or flat-plate AGM products.
Our SpiralCell design has about 30 internal parts, where traditional flat-plate batteries can have more than 120 internal components. One of our internal components is a continuous cast strap, which joins adjacent cells and eliminates welds, which add resistance and corrosion points between the cells. A cast strap is unique to Optima, proprietary, more expensive, and more difficult to manufacture, but it is a process that gives superior performance. A larger and/or better-designed, manufactured or connected strap will allow better high-current flow due to lower internal resistance, which can be reflected in the CCA rating. This also allows the Optima design to use taller cells, which results in more active material.
Most batteries will never be used anywhere near to their full potential, spending most of their lifespan within 20% of a full state of charge. Of all the folks who use our batteries, I don't know of any who will discharge them more deeply and more often, while having more money on the line, than tournament anglers. When $500,000 is at stake, it's not about free batteries from sponsors, it's about using products that they know will continue working when they need it most. If there were concerns about the capacity of our batteries or reliability, no one in competitive fishing, let alone guys like Chris Lane and Edwin Evers, would go near our products, even if we paid them.
Jim McIlvaine
eCare Manager, OPTIMA Batteries, Inc.
www.pinterest.com/optimabatteries