CONTIGRID™
HAZELETT | RYAN GORE, VP Sales & Marketing
CONTIGRID™
Integrating Proven Process Technology with Next-Generation Grid Manufacturing
As battery manufacturers expand production capacity and seek greater process efficiency, the limitations of traditional grid manufacturing approaches are becoming increasingly evident. Fragmented equipment layouts, multiple suppliers, and disconnected process steps introduce unnecessary complexity, variability, and project risk.
In response, Hazelett and Eagle Oxide introduce CONTIGRID™, a fully integrated lead grid manufacturing platform designed to deliver a continuous, synchronized process from melt to finished grid. Beyond just the equipment, a deep process and integration experience is offered, unique in the industry.
A FOUNDATION BUILT ON PROVEN BATTERY GRID TECHNOLOGY
To produce the high throughput of nearly 1 million grids per day, a melting furnace capable of over 16MT of melt rate is needed. The Eagle lead melting system provides this capability via immersion burner tubes vs. external burners and a crucible. A single pot of 45MT capacity handles new lead feed as well as the high rate of chip return easily, facilitating a smaller footprint and automatic alloy control. At the heart of CONTIGRID™ is Hazelett’s well-established twin-belt continuous casting technology, widely recognized for its capability to produce high-quality lead alloy strip in a stable and controlled process environment.
The Hazelett® LS1800 twin-belt caster operates using two opposing, water-cooled steel belts that form a moving mold, supported by precision back-up rolls and sealed by edge dam systems. This design enables continuous casting of lead strip with consistent geometry and metallurgical properties.
Typical operating parameters for the LS1800 platform include:
Casting speeds of up to 7 m/min
Strip thickness ranges from approximately 9–15 mm
Output capability exceeding 15 MT/hr depending on strip dimensions
This casting approach provides a stable, continuous feedstock for downstream rolling and grid production – forming the technological backbone of the CONTIGRID™ concept.
FROM CONTINUOUS CASTING TO CONTINUOUS GRID PRODUCTION
While continuous casting and rolling have long been proven technologies, traditional grid production still relies on multiple interconnected systems that often operate independently. CONTIGRID™ addresses this challenge by integrating the entire production chain—from molten metal to finished grid—into one balanced process.
The rolling process has been optimized beyond previous work to provide the best corrosion resistant material in the highest throughput rate. Thickness can be .55mm up to 1.5mm with automatic tensioning and roll schedule adjustments. Carefully controlled cooling of the rolls and strip provide the favorable metallurgical properties for a stamped grid design.
The coil handling equipment is also automated such that no manual intervention is required during coil changes that occur in less than a minute. The punch press utilized in the grid stamping process has been modified to accommodate the lead environment and is capable of rates up to 500 spm and 125 Ton load. Well-developed die designs that are double wide produce 2 grids with every stroke.
CONTIGRID™ is not simply a collection of equipment—it is a fully engineered production platform that integrates:
- Eagle Oxide’s state-of-the-art alloy melting and controlled metal feeding equipment
- Hazelett’s LS1800 Twin-Belt Caster
- Precision high-load rolling mills with integrated tensioning and strip cooling control
- Automated coil handling up to 12,000 lbs and 150 cm in diameter
- Progressive grid stamping at 800 grids per minute
- Precise, robust die designs with integratedlubrication for high uptime
- Best in class push-pull servo feeders
- Best in class push-pull servo feeders
Each stage is engineered to operate in synchronization with the next, eliminating bottlenecks and reducing manual intervention throughout the process.
ENGINEERING INTEGRATION AT EVERY STAGE
A key advantage of CONTIGRID™ lies in its system-level engineering. Rather than optimizing individual machines, the platform is designed as a complete manufacturing ecosystem, where process variables—such as casting speed, strip thickness, and downstream stamping rates – are balanced across the entire line.
For example, the upstream metal feeding system ensures stable and controlled delivery of molten lead into the casting mold through systems such as tundish flow control and automated pool level monitoring. The alloy to the casting process is automatically controlled by adjusting the ratio of elements to maintain specification. These controls allow the casting process to operate under consistent thermal and flow conditions, which directly impacts downstream product quality.
This results in strip that is both dimensionally consistent and suitable for high-speed downstream processing.
AN ADVANTAGE ON THE MARKET: SCALE CAPACITY WITH CONFIDENCE
For battery manufacturers, the decision to invest in new grid capacity is no longer just about adding equipment—it is about reducing risk, accelerating timelines, and maximizing return on investment.
CONTIGRID™ is specifically designed to address these priorities.
One of the most significant challenges in traditional grid line projects is the coordination of multiple vendors and interfaces. Each additional interface introduces risk—whether in engineering responsibility, commissioning timelines, or long-term operational performance.
CONTIGRID™ addresses this directly by providing:
- A single, integrated process flow
- Coordinated, experienced engineering across all stages
- A unified approach to commissioning and startup – one source for everything
This reduces the number of critical interfaces and shortens the path to full production, enabling manufacturers to bring new capacity online more efficiently.
OPERATIONAL BENEFITS FOR BATTERY MANUFACTURERS
By combining Hazelett’s casting technology with Eagle Oxide’s expertise in downstream systems, CONTIGRID™ delivers measurable operational advantages:
IMPROVED
THROUGHPUT
A continuous, synchronized process enables higher overall line utilization compared to batch or semi-integrated approaches.
ENHANCED PRODUCT
CONSISTENCY
Integrated process control across casting, rolling, and stamping improves dimensional accuracy and repeatability of the final grid. Expected throughput of 1million grids per day based upon balanced casting and rolling to support 800 grids per minute and 87% OEE.
MATERIAL
EFFICIENCY
The continuous strip process minimizes handling losses and supports improved yield across the production line.
SIMPLIFIED
EXECUTION
Integrated supply reduces project complexity, accelerates commissioning, and provides clearer accountability throughout the project lifecycle.
A COLLABORATIVE APPROACH BACKED BY EXPERIENCE
CONTIGRID™ is the result of long-standing collaboration between Hazelett and Eagle Oxide, combining expertise in:
- Continuous strip casting systems
- Lead handling and process control
- Grid stamping and downstream battery manufacturing
This collective experience – spanning decades of installed systems and real-world operation – has been consolidated into a single, unified offering designed to meet the needs of modern battery manufacturing facilities.
POSITIONING FOR THE NEXT GENERATION OF PRODUCTION
As the industry continues to evolve, manufacturers are increasingly focused on scalability, consistency, and reduced operational risk. CONTIGRID™ represents a shift toward fully integrated production platforms that align technology, engineering, and execution into a single solution.
By building on proven casting fundamentals and extending integration across the entire production chain, CONTIGRID™ provides a practical and scalable pathway for the next generation of lead grid manufacturing.
