Introduction:

The battery industry is constantly evolving, driven by the quest for greater efficiency, reduced costs, and, crucially, increasing sustainability. For decades, producing lead slugs—a fundamental component of lead-acid batteries—has been synonymous with gas furnaces, molten lead, and exhaust fumes. While the market now offers a few “green alternatives,” it’s vital to look beyond the surface.

At CAM, we have developed and perfected the Lead Shaver, a machine that is redefining production standards. We will show you why our cold-working technology is the definitive solution, not just against the old methods, but also against new alternatives that hide significant operational costs.

The Traditional Method: A Cost We Can No Longer Afford

The conventional process of melting lead in a gas-fired furnace is burdened by issues that no modern manufacturer can ignore:

1. Exorbitant Energy Costs: Furnaces consume up to $90$ kWh per tonne of lead, making them highly vulnerable to energy price volatility.
2. Material Waste (Dross): The process loses approximately 3% of lead to dross, generating $\approx 480$ tonnes of waste per year for high-volume producers.
3. Environmental Burden: High CAPEX and OPEX due to the need for complex stack filtration and fume management systems.

For a producer running 2 million batteries annually, the total estimated annual loss in the Eurozone (due to energy and material waste) is over €1.2 Million.

The False Promise: Why the “Cubic Machine” Alternative Falls Short

In the search for cleaner production, some companies have introduced machines that eliminate melting but still use mechanical methods, such as the Cubic Machine. This technology typically works by slicing the lead ingot into thin strips and then pressing them into cube-shaped slugs using a male/female drum system.

While this alternative eliminates the furnace, it introduces a new and critical hidden cost:

• High Maintenance Cost from Wear and Tear: The core of the Cubic Machine is the stamping or pressing mechanism (the male/female drum). Due to the high forces and repetitive impacts necessary to cold-form lead cubes, this drum assembly experiences significant, rapid wear.
• Frequent Drum Replacement: The necessity for frequent and costly replacement of this drum assembly creates an unpredictable and onerous operational expense that severely diminishes the machine’s profitability advantage over time.

The Cubic Machine might look “green” on paper, but its high, recurring maintenance costs reveal a false efficiency.

The CAM Lead Shaver Revolution: True Efficiency, Zero Hidden Costs

The CAM Lead Shaver is the only technology that delivers true efficiency without dangerous trade-offs. Instead of stamping the lead (which causes high mechanical stress), our machine performs a clean, continuous “shaving” process on a solid bar.

The Lead Shaver technology delivers a reduction in energy consumption of approximately 90% and recovers that crucial 3% of lead, generating enormous immediate savings. More importantly, it achieves this with robust mechanical components that require only standard, predictable maintenance, completely avoiding the catastrophic, recurring costs associated with the Cubic Machine’s stamping drum.

The Lead Shaver offers a path to production that is cleaner, vastly more efficient, and truly predictable.

Ready to calculate your guaranteed savings, without hidden costs?

Don’t let the costs of the past or the hidden costs of the competition slow you down. Discover your true potential for savings and sustainability.

Click here to request your FREE, personalized “No Worry Report”: https://www.cam-srl.com/no-worries-report/

In the intricate world of battery manufacturing, every single stage of the process is crucial to the quality and longevity of the final product. Among these, plate curing is an often-underestimated yet fundamentally important step. This is where a simple lead paste transforms into a solid, robust plate, ready to house the electrochemical reactions that will power our vehicles and devices.

But what exactly happens during curing? And why can the choice of curing technology make such a profound difference?

The Science Behind Curing: From Paste to Functionality

Imagine freshly pasted plates: they are an “inactive” paste, primarily composed of free lead. The objective of curing is twofold:

1. Solidification: To transform this malleable paste into a solid, robust structure that can withstand the stresses of the manufacturing process and, subsequently, the operational environment within the battery.

2. Oxidation of Free Lead: To reduce the free lead content by converting it into lead oxide. This step is vital because free lead is less efficient in electrochemical reactions and can lead to performance issues and reduced battery life.

For this oxidation to occur, the plate needs a key element: oxygen. Traditionally, oxygen is supplied through humidity, often in the form of atomized water introduced into curing chambers.

The Traditional Approach: Atomized Water and Its Limitations

For years, the standard method for humidifying plates has been the use of atomized water. Water, in the form of tiny droplets, is introduced into the environment, providing the necessary humidity for the oxidation reactions.

However, this approach, while functional, has inherent limitations:

• Inhomogeneous Distribution: Water droplets, due to their mass and surface tension, tend to settle or fail to penetrate uniformly into every nook and cranny of the plates. This can lead to inhomogeneous curing, with some areas being over-cured and others under-cured, affecting the overall quality of the plate.

• Longer Cycle Times: To compensate for poorer penetration and ensure sufficient humidity, curing cycles can require more time.

• Energy Consumption: Atomizing and heating large volumes of water can be energy-intensive.

The Steam Cure Revolution: The Power of 1 Bar Saturated Steam

At Steam Cure, we have thoroughly investigated these limitations and developed a game-changing solution: our curing chambers utilize saturated steam at 1 bar to generate humidity, in combination with a horizontal laminar flow.

But why is steam so superior to atomized water? The answer lies in its density.

Let’s consider the numbers:

• The density of saturated steam at 1 bar is approximately 0.590 kg/m3.

• The density of water at $100\text{°C}$ is approximately 958 kg/m3.

This difference is astronomical! Steam, being infinitely less dense than liquid water, behaves radically differently:

1. Unparalleled Penetration: Thanks to its low density and gaseous nature, steam can diffuse and penetrate into every single micropore and interstice of the plate. It doesn’t just “wet” the surface but completely envelops the plate structure.

2. Perfectly Homogeneous Curing: This uniform penetration ensures homogeneous curing at every point of the plate, regardless of its position within the chamber. Every plate, from the outermost to the innermost, receives the same humidity and thus cures perfectly. This eliminates quality variations and ensures greater batch uniformity.

3. Reduced Cycle Times: The efficiency of steam diffusion, combined with our horizontal laminar airflow system, accelerates the oxidation and curing process. The result is a significantly lower cycle time, leading to increased productivity and flexibility for your production line.

4. Greater Energy Efficiency: The steam system is designed to maximize energy efficiency, reducing waste and long-term operating costs.

The Future of Curing is Here

Investing in advanced curing technology like that offered by Steam Cure is not just an upgrade; it’s a strategic move for your business. It means:

• Improved Product Quality: More uniformly cured plates mean higher-performing and more reliable batteries.

• Increased Productivity: Faster curing cycles mean more plates produced in less time.

• Reduced Waste: The homogeneity of the process reduces the likelihood of defects related to inadequate curing.

• Competitive Advantage: Adopting cutting-edge technologies positions you as a leader in the industry.

If quality, efficiency, and innovation are priorities for your battery production, Steam Cure’s curing chambers represent the next evolutionary step. Don’t settle for the standard when you can surpass it.

If you’re ready to explore how Steam Cure’s vapor technology can transform your plate production, we invite you to learn more.

Click here to contact one of our experts and discover all the details.

Hey there, lead battery manufacturers!

Today, I want to take you on an exclusive journey, a peek behind the curtain of our premium remote assistance service. If there’s one thing we’ve learned at CAM, it’s that in the fast-paced world of battery production, every single second of downtime is a cost, a lost opportunity. And that’s where we come in, with our promise of reliability and operational continuity.

More Than a Price Tag: A Guarantee of Peace of Mind

We always say it: the value of a CAM machine isn’t just measured by its initial price. The true value lies in consistent quality, production coherence, and, most importantly, the certainty that your plants will operate smoothly without interruptions. Our remote assistance embodies this philosophy. It’s our way of standing by your side, wherever you are, 24/7.

Our “Window to the World”: TeamViewer in Action!

Have you ever wondered how we manage to provide such comprehensive support? Our ace in the hole is TeamViewer. It’s not just software; it’s our digital bridge that allows us to connect in real-time with our equipment installed in every corner of the globe. Imagine having our engineers directly in your plant, ready to intervene, analyze, and troubleshoot. That’s exactly what happens!

A Virtual Tour of CAM Plants in Production!

And now for the most exciting part! In the video I just published on my YouTube channel, I show you live how all of this works. Get ready for a virtual “teleportation” to our plants!

• Germany: Precision and Continuous Monitoring. In the video, I take you to a cutting-edge company in Germany. You’ll be able to see our ball mills and oxide area systems operating at full capacity. I’ll show you how our technicians, comfortably from our offices, can monitor every single parameter: from temperatures to flows, from pressures to alarms. You’ll see how we manage to read the machine’s “vital signs,” anticipating potential problems even before they arise!

• Colombia: The Efficiency of Our Curing Chambers. Then, we move to Colombia, where our curing chambers are working tirelessly. Through the remote connection, we can view the process progression in real-time, ensuring that every battery is maturing perfectly. It’s incredible to see how we manage to guarantee high-quality standards even thousands of kilometers away!

• Portugal: The Versatility of Lead Shavers. And to conclude our tour, we land in Portugal. Here, our lead shavers are the stars. I’ll show you how our engineers can not only monitor but also provide guidance or even, with your permission, make small adjustments remotely to optimize performance. It’s a perfect example of how remote assistance is not just reactive, but also proactive.

Flexibility and Security: Our Priority

We know that cybersecurity is paramount. That’s why, if your company has very strict IT policies, no problem! We are able to establish temporary and controlled connections, precisely for the time needed for intervention, ensuring maximum security and adherence to your procedures.

Ready to Revolutionize Your Production?

If you’re tired of unexpected downtimes and want to ensure your lead battery production is always operating at its peak capacity, CAM remote assistance is the solution you’ve been looking for.

Watch the video for a complete experience and then… let me know what you think in the comments below! Do you have questions? Want to dive deeper? Send us an email or click the link in the video to download our CAM Box and discover more about how our solutions can transform your production.

We look forward to working with you for an interruption-free future!

In the world of industrial manufacturing, innovation often happens behind the scenes, in the very heart of the machinery. For lead oxide production, that innovation is found in the CAM MOP ball mill, and specifically, in its unique internal water spray cooling system.

If you’re involved in battery manufacturing, lead recycling, or any industry requiring high-purity lead oxide, you know that the quality of your raw material directly impacts your final product’s performance and longevity. At CAM, we’ve focused on perfecting this foundational step.

Beyond the Surface: The Core Difference in Cooling

Most ball mills on the market rely on external cooling mechanisms. While these serve a basic purpose, they often come with compromises. At CAM, we challenged the status quo and developed an internal water spray cooling system. Here’s why it’s a game-changer:

1. Precision Temperature Control: The Key to Superior Quality

The most critical factor in producing high-quality lead oxide is maintaining optimal temperature during the milling process. High temperatures can lead to the formation of orthorhombic lead oxide (ortho-PbO).

• Ortho-PbO is characterized by an oxygen ion surrounded by four lead ions. This structure makes the crystals prone to flaking, which directly translates to low conductivity in the final product. For battery applications, this means compromised performance and a shorter lifespan.

Our internal cooling system provides direct and immediate temperature control. By spraying water internally, we can precisely regulate the heat generated during milling, preventing those detrimental temperature spikes. This meticulous control ensures the formation of 100% tetragonal lead oxide (tetra-PbO).

• Tetra-PbO, formed at lower, controlled temperatures, has a distinct “snowflake” shape where each Pb2+ ion sits above a $PbO\_4$ pyramid with identical $Pb-O$ distances. This unique molecular structure results in significantly higher acid absorption—a vital property for high-performance batteries. The difference in conductivity and acid absorption between ortho-PbO and tetra-PbO can drastically impact the efficiency and lifespan of your final products.

2. Unprecedented Durability: A 30-Year Lifespan for Your Investment

Beyond product quality, our innovative cooling method offers remarkable benefits for the mill itself. With internal water spraying, the water is instantly absorbed by the material inside the cylinder. This prevents any thermal shock or long-term damage to the mill’s cylinder.

Consider the alternative: external cooling systems often suffer from continuous limescale buildup. This requires frequent, costly maintenance and cleaning, leading to significant downtime. More importantly, limescale accumulation can cause structural damage to the cylinder over time, drastically reducing its operational lifespan.

This is why CAM MOP ball mills can confidently guarantee an incredible 30+ years of cylinder life. It’s not just about producing better lead oxide; it’s about providing a robust, reliable, and exceptionally durable piece of equipment that serves your business for decades.

Invest in Excellence: Why CAM MOP Mills are the Smart Choice

Choosing a CAM MOP ball mill means more than just acquiring machinery; it means investing in:

• Consistently superior product quality, which enhances the performance and market value of your end products.

• Greater operational efficiency through reduced waste and optimized processing.

• Significantly lower maintenance costs and minimal production downtime.

• Exceptional equipment longevity, safeguarding your capital investment for the long term.

Don’t settle for conventional methods that might limit your product’s potential and increase your operational burdens. Embrace the innovation that sets CAM MOP ball mills apart.

Ready to elevate your lead oxide production and secure a competitive edge?

Discover how our unique technology can transform your operations. Visit our landing page, fill out the form, and get in touch with a CAM expert today!

www.cam-srl.com/landing-page

See you at the BCI Convention in Texas

We are thrilled to announce our participation in the prestigious BCI Convention, taking place in San Antonio, Texas, from May 4th to 7th, 2025. For CAM, being present at this globally significant event for the lead-acid battery industry is a source of great pride.

Why should you definitely visit us?

The answer is simple: for over fifty years, precisely since 1967, CAM has been a global benchmark in the production of specialized equipment for lead oxide and curing chambers. Our exclusive dedication to this sector has allowed us to develop unique know-how and rely on a team of highly specialized technicians. Today, over 50 plants worldwide depend daily on the reliability and efficiency of our machines.

But we don’t stop there! We are delighted to share another exciting piece of news with you: for the second consecutive year, CAM is a finalist for the prestigious BCI Innovation Award! This year, our innovation that has captured attention is the Lead Shaver XL, a revolutionary and unique method for the production of lead billets for ball mills, completely free of gas emissions.

Don’t miss the opportunity to:

• Meet our experts: Our managers will be present at the exhibition to answer all your questions and discuss your specific needs.

• Discover the Lead Shaver XL: Come and see firsthand this cutting-edge technology that is redefining industry standards.

• Explore our solutions: Learn about the full range of our equipment for lead oxide and curing chambers.

Book your appointment now!

Would you like to arrange a dedicated meeting with our team during the BCI Convention? Click below to schedule your visit:

https://www.cam-srl.com/get-quote/

Get a sneak peek of the Lead Shaver XL!

If you’re curious to see our innovative Lead Shaver XL in action, don’t miss the presentation video available here:

We look forward to welcoming you to the BCI Convention in San Antonio! It will be an unmissable opportunity to discover the latest innovations and strengthen partnerships in the world of lead-acid batteries.

See you in Texas!

Introducing a Timeless Technology

In our recent video, we showcased a CAM ball mill that was installed in 2000. This mill, like many others in our extensive fleet, continues to operate with remarkable efficiency and durability. The secret lies in our unique design and manufacturing processes.

The Heart of the System: Gear Transmission

One of the standout features of CAM ball mills is the crown-pinion gear transmission. This robust system has proven to be exceptionally reliable over the years. In fact, after installing 62 ball mills worldwide, we have yet to replace a single crown gear. This testament to durability is a direct result of our meticulous engineering and high-quality materials.

Automation for Efficiency

Our ball mills are designed with automation in mind, making operation as simple as pressing a button. With minimal operator intervention, you can achieve consistent and high-quality lead oxide production. Once the process is initiated, the mill efficiently grinds the material to the desired particle size.

A Specialized Filtration System

The horizontal bag filter is another unique component of our lead oxide production systems. This filter is specifically engineered for processing lead oxide and consists of three chambers: a pre-chamber, a central chamber with horizontal bags, and an exit chamber. This multi-stage filtration process ensures exceptional product purity.

A Global Leader in Lead Oxide Production

With 62 ball mills installed worldwide, CAM has established itself as a global leader in lead oxide production equipment. Our sole focus on lead oxide and curing chambers for battery plates allows us to offer unparalleled expertise and customized solutions.

Join the Leaders

If you’re looking to gain a competitive edge in the battery market, investing in CAM equipment is a wise choice. Our durable, efficient, and automated ball mills will help you produce high-quality lead oxide and improve your overall production process.

For more information, please visit our website at www.cam-srl.com

What does a cheese grater and a plate of pasta have to do with lead and lead batteries?

I’ll explain it to you right away.

Let’s do a technical review:

the lead acid battery is a set of energy cells. Each cell has a series of positive and negative plates which, connected in an appropriate way, create an energy accumulation.

Each plate (positive and negative) is composed of:

– lead grid

– mixing of lead oxide and additives.

To produce lead oxide a ball mill is used, one of these is the CAM MOP, which ONLY produces 100% tetragonal lead oxide. (but this is not the topic of the day).

To produce lead oxide, lead cylinders must be inserted inside the mill, which creates dust (lead oxide) through abrasion.

Lead cylinders can be produced in 2 ways:

1- melt the lead ingots and then solidify the liquid lead with a cylinder caster

2- Grate the lead ingot like cheese.

The first solution is old, a lot of energy consumption, smoke emissions, chimneys etc…

The second is the future. Simply grate the lead ingot like a cheese with the grater:

– up to 90% energy savings (cost cutting)

– healthy working environment (no lead levels)

– no chimneys

Here is the video of the LEAD SHAVER:

https://www.youtube.com/watch?v=-GhA5LOTvbo&t=1s

Now you will ask me: ‘and what about the quality of the oxide?’

The quality of the oxide remains the same, without further ado I advise you to directly read the testimonials of people using this technology.

https://www.cam-srl.com/testimonials/

What does a cheese grater have to do with lead?

Because the LEAD SHAVER was designed while Armando and Fernando Marfisi were eating a plate of pasta: from there, the lighting…

If you want to know the story in detail click on the link below and watch the video:

https://www.youtube.com/watch?v=ZfcK_y3rxD0&t=83s

Producing lead acid batteries in a GREEN way is POSSIBLE TODAY!

Start winning in the market by starting with MOP lead oxide and LEAD SHAVER.

If you don’t know CAM and want information I recommend you download the CAM BOX, a tool kit for operations, quality, engineering and CEO managers.

Click on the link below:

https://cam-srl.systeme.io/landing-page

If you use CAM equipment instead, send your request for a LEAD SHAVER and we will send you an
EXCLUSIVE OFFER!

Have a Good day

See you on the next episode

Francesco Marfisi

[FASMELT] If you can imagine it, you can make it happen.

What does innovation mean?

Go outside the box

out of budget,

outside of what the market imposes on you.

Thus FASMELT was born

Categories are often stagnant because there is no one who has the courage to break the mold:

‘your machine is innovative but my customer doesn’t approve of it…’

This is the classic response of the manager of a big company.

Big companies that can’t progress because their big client rejects progress.

Without progress we cannot move forward, and companies (even giants) close.

(See Kodak, Blockbuster, Nokia, Borders, Blackberry)

To name just a few that you will surely know.

But what does it mean to innovate?

Make things better – improve people’s lives – cut costs – cut emissions.

Stop!

If innovation does not do these, or one of these, things, it is NOT innovation.

One morning, while I was preparing coffee for my wife on the induction hob, I thought:

“Why can I make coffee in 30 seconds and I can’t dissolve lead the same way?”

Thus the idea of ​​Fasmelt was born.

From there, together with the genius of Matteo Marfisi, today it is possible to melt lead in 20 minutes, no longer 4 hours.

But, what is a FASMELT for?

Is the lead-acid battery market innovating?

YES

1. Improves production times (start & stop of ovens)

2. improves the life of operators (no more waste by hand)

3. cuts producers’ costs (cuts 60% of energy)

4. does not emit gas into the environment

The time to change is TODAY.

Not tomorrow, not when your big client decides.

Tomorrow, big customers may no longer exist if they do not embrace progress.

I’ll wait for you at the #ELBC event in Milan where I will talk about the real FASMELT case

If you don’t want to wait, click on the link below and book a conference call with us:

www.cam-srl.com/get-quote

Do you know how to build lead oxide conveyors?

Lead oxide is a powder that compacts, so it is necessary to have robust conveyors for handling.

Welcome to this new article.

Today I want to show you how to build lead oxide.

Lead oxide has a bulk density of approximately: 3500 – 3700 kg/m3.

So it’s a heavy powder.

Apart from this,

Lead oxide packs.

What does it mean:

it feels moist to the touch, therefore not dry, and creates blockages.

For prolonged storage times (more than 3 days) it begins to harden.

This is a problem if you don’t know the product well.

For this reason, I want to show you the 3 types of lead oxide conveyors.

1- screw conveyor

2- Flat conveyor

3- bucket elevator

1- Screw conveyor

It is the most common in lead battery plants.

It is the cheapest and easiest to reproduce.

Here too, pay attention to manufacturing.

It must be constructed correctly because lead oxide can break the internal mechanics of the screw.

We recommend screw conveyors for lengths up to 6 m.

2- Flat conveyor

It is THE conveyor for lead oxide.

It has very strong mechanics, with a very large pinion.

The conveying takes place via a scraping chain.

The flow rate is 4 t/h.

This conveyor can reach up to 60 m.

In addition to this, it has the advantage of having only one electric motor, therefore lower breaking points and lower maintenance compared to screw conveyors.

3- Bucket elevator

The elevator is used to convey the oxide upwards.

It can reach up to 12 meters.

Thanks to the robustness of the buckets and its geometry, there are no product losses along the way.

Here are the types of conveyor.

When you decide to install lead oxide ducts, choose them specific to lead oxide.

Do not install conveyors for other powders because you will make a bad investment and then you will have to buy them again.

Lead oxide is not flour.

If you want to get in touch with me send me an email to cam@cam-srl.com

If you are not familiar with CAM equipment, click on the link below to receive the CAM BOX for FREE.

https://cam-srl.systeme.io/landing-page

Have a Good day

See you on the next episode

Today we talk about the grain size of lead oxide.

As it should be, and in addition to the grain size, what is the other fundamental parameter to have perfect adhesion between the grid and the paste.

Today we talk about grain size, apparent density and much more

Let’s start with theory.

The first difference is between the particle size distribution of a ball mill and Barton.

The average diameter of ball mills oxide is smaller than the diameter of barton oxide.

This gives the ball mill process a higher acid reactivity and absorption

Here is the graph of the grain size distribution of MOP oxide.

What is the uniqueness of MOP oxide compared to others?

A MOP mill GUARANTEES a grain size of less than 44 microns.

The grain size concistency of the MOP ball mill is fundamental

Another important factor is the bulk density

The bulk density of a MOP oxide is between 1 and 1.4 g/cm3

But the real secret is the molecular structure of M O P lead oxide: it is ONLY 100% tetragonal.

Why is this?

Because thanks to tetragonal oxide there will be a perfect and strong adhesion between the grid and the active material.

This means:

high cranking power and guaranteed battery life

If you don’t already use CAM equipment, click on the link below and receive all the free resources like the CAM BOX

https://cam-srl.systeme.io/landing-page

I am Francesco Marfisi from CAM – THE lead oxide specialists

see you in the next episode