Reducing the Environmental Impact of Battery Manufacturing
Sustainability is increasingly a responsibility shared by manufacturers, employees, customers, and the communities they are a part of. At Trojan Battery, that responsibility is reflected in an ongoing effort to reduce the environmental impact of manufacturing our industry-leading energy solutions while continuing to improve productivity and operational performance.
Through investments in advanced equipment, more efficient battery manufacturing practices, and proactive facility maintenance, Trojan is steadily reducing the carbon footprint associated with producing batteries. These initiatives are designed to deliver lasting environmental benefits while simultaneously creating more efficient and safer manufacturing operations.
The results are measurable. Since introducing its sustainability initiatives, Trojan has lowered CO2e (carbon dioxide equivalent) emissions per battery manufactured by 6%. In the first half of 2026, the company also surpassed its 2.5% improvement target as additional manufacturing enhancements continued to generate results.
These gains are occurring while Trojan increases the efficiency of manufacturing its industry-leading battery portfolio. Award-winning Trojan AES AGM, OnePack lithium, and flooded lead acid batteries are all assembled using sustainable practices.
Battery manufacturing upgrades
Leadership commitment has been essential to this progress. With support from executive management, Trojan is making upgrades throughout its manufacturing operations in three primary areas:
Green Practices: New production methods are improving operational efficiency, reducing utility expenses, and enhancing workplace safety.
Equipment: Manufacturing systems ranging from facility lighting to automated robotics are being upgraded to use energy more efficiently.
Maintenance and Operational Optimization: Routine facility and equipment inspections help identify potential problems before they affect production. This approach can prevent inefficiencies that increase operating costs, energy consumption, and emissions.
More efficient manufacturing
Across Trojan’s seven manufacturing facilities, equipment and infrastructure improvements are being implemented with both sustainability and productivity in mind.
Robotics: Deploying automation systems is producing efficiency gains of 10% or more compared with manual operations. Integration of robotics can also reduce the potential for employee injuries.
Compressed Air Systems: Manufacturing cycle times are less due to enhancements made to air compressors and distribution lines. These pneumatic systems lower energy usage, thereby reducing the need for on-site fuel combustion. They can lower direct process emissions, contributing to cleaner manufacturing operations.
Assembly Equipment: Some locations have improved pasting and continuous casting machinery. Production throughput is more efficient, helping reduce CO2e emissions on a per-battery basis.
High-efficiency Lighting: Long-used inefficient lighting is being replaced with modern energy-efficient LED technology to reduce electricity consumption. Motion sensors and timers provide additional savings by ensuring lights operate only when necessary. These improvements extend beyond offices and production areas to warehouses, storage spaces, and other locations that may remain unoccupied for extended periods.
Processes centered on efficiency and safety
Reducing energy consumption is an important consideration whenever Trojan evaluates a new manufacturing process. Employee health and safety are also central to the decision-making process.
Before automation is introduced, Trojan evaluates the expected operational and environmental benefits. Manufacturing-floor layouts are analyzed to determine how equipment and processes can be arranged more effectively from both an efficiency and ergonomic perspective.
This approach can reduce repetitive-motion activities and eliminate some physically demanding manual tasks. The result is a manufacturing environment designed to improve productivity while reducing the potential for workplace injuries.
Proactive approach to maintenance
Investing in advanced manufacturing technology provides limited value if that equipment does not continue operating at peak performance. For that reason, Trojan has established monthly preventive-maintenance programs throughout its facilities.
Designated teams regularly inspect departments to verify that manufacturing equipment and supporting systems are performing as intended. These inspections help maintain production throughput while supporting the company’s sustainability objectives.
Pneumatic equipment is a good example. A relatively small air leak can reduce system pressure, forcing equipment to consume additional electricity while potentially slowing throughput. Routine inspections allow leaks to be detected and repaired, helping control energy use and utility expenses.
The monthly maintenance process is also helping Trojan identify new ways to enhance production as a battery manufacturer. As these opportunities are evaluated, additional measures can be implemented to support continuous progress in sustainability, manufacturing performance, and employee safety.
When a battery manufacturer is also a sustainability partner
Trojan’s sustainability strategy extends beyond its own facilities. Battery technologies can also help customers pursue their environmental, sustainability, and governance (ESG) objectives.
Sustainability considerations extend to the end of a battery’s useful life. Trojan’s standard AGM and flooded batteries are 98% recyclable, and as much as 50% of reclaimed materials can be incorporated into the production of new batteries using these chemistries.
Together, these initiatives demonstrate how improvements in manufacturing technology, operational processes, maintenance, and battery performance can contribute to a broader sustainability strategy—one that benefits Trojan, its employees, customers, and the communities in which it operates.