Rotajet provides complete, turnkey systems for recycling lead-acid batteries – safely, efficiently, and profitably. With up
to 96% of lead-acid batteries recycled across the G7, this process is one of the most successful in the industry, largely
due to the value of recovered lead and plastics like PP and ABS.
Lead-acid batteries are one of the most successfully recycled products in the world, with recycling rates reaching up to 96% across developed nations.
This high success rate is largely driven by the economic value of the materials recovered—particularly lead and polypropylene plastic. However, recycling isn’t just about value recovery. It’s also a matter of environmental responsibility and public health.
These batteries contain highly toxic substances, including lead, sulphuric acid, and other heavy metals. If improperly disposed of, these substances can leach into soil and groundwater, contaminate ecosystems, and pose serious health risks to both humans and wildlife. Lead, for example, is a potent neurotoxin that can cause irreversible developmental and neurological damage, especially in children. Even small amounts can accumulate in the body over time, leading to chronic illness.
These batteries are commonly found in:
Rotajet’s systems are designed to separate valuable materials – lead, PP, PVC, ABS, and rubber – from harmful contaminants like lead paste and sulphuric acid, delivering clean, resale-ready granulate.
Because over 90% of the components in lead-acid batteries are potentially harmful, it’s essential that they are processed using the right equipment and procedures. Proper recycling ensures that valuable materials are safely recovered and that harmful elements are neutralised, removed, or contained.
At Rotajet, our recycling systems are engineered to handle every step of the process with maximum safety and efficiency. From neutralising acid and separating plastics to granulating and drying the recovered material, our solutions ensure that lead-acid batteries are recycled in a way that protects both people and the planet.
The Container Recycling Process
Rotajet’s container recycling process ensures that each step is optimized for efficiency, cleanliness, and material recovery. Here’s an overview of the typical process flow:
First, the batteries are fed into a powerful shredder, typically via a flighted incline conveyor. The shredder reduces them to around 70mm, increasing surface area for more effective downstream processing.
Shredded material enters a sink-float tank, where heavier contaminants—like stones, metals, glass, PET, PVC, and ABS—sink, separating them from the HDPE. This step ensures cleaner material for the next stage.
After shredding, the material moves to a wet granulator. This high-performance machine ensures a consistent particle size. Built for tough environments, our granulators deliver reliable performance.
A high-speed friction washer (up to 3000rpm) removes remaining contamination from the plastic. Its intense spinning action, combined with wash liquor, ensures a deep clean.
After washing and granulation, our mechanical dryers deliver the most efficient plastic dewatering, achieving under 5% moisture in rigid materials.
A zig-zag separator removes fines and light contaminants, ensuring the granulate is clean and high-quality—ready for extrusion into new products.
Rotajet’s lead-acid battery recycling systems are built for safe operation, environmental compliance, and consistent performance. Every machine is tested and trialled before leaving our facility, ensuring your system is tailored, reliable, and ready for industrial use.
Ready to start recycling lead-acid batteries? Our technical advisors can help design the right system for your needs.
