For dealers and their customers alike, selecting the right motive power solution is a critical decision—and not all batteries are created equal. While most industrial batteries appear similar from the outside, HAWKER® Thin Plate Pure Lead (TPPL) technology represents a fundamental advancement in battery design that transforms performance from within.
In this article, we’ll take you behind the scenes to explore TPPL technology and how it empowers you to meet the demands of a world, a supply chain, and a market landscape in constant fluctuation.
So, what exactly is a Thin Plate Pure Lead battery, and why is it so effective? HAWKER® TPPL battery technology revolutionizes traditional battery construction through several key innovations:
Unlike conventional batteries using lead alloys, HAWKER® TPPL batteries feature 99.99% pure lead plates. This exceptionally pure material allows for:
● Dramatically low internal resistance
● Superior conductivity
● Enhanced energy efficiency during both charge and discharge cycles
● Reduced heat generation during operation
As the name suggests, TPPL technology employs significantly thinner lead plates than conventional flooded lead-acid batteries. This design dramatically increases the surface area available for electrochemical reactions, resulting in enhanced charge acceptance, higher power density, and improved efficiency.
● 0.7mm thick pasted plate design (versus 2-4mm in traditional designs)
● Significantly higher positive plate count within the same physical battery dimensions
● Maximum surface area exposure for chemical reactions
● Load is shared across all exposed plates
● Faster charging capabilities
● Improved power density
The electrolyte in TPPL batteries is absorbed in a micro-porous glass mat, providing optimal contact between the electrolyte and the lead plates. This eliminates the need for watering and minimizes the risk of acid spills, making TPPL a safer and more environmentally friendly solution.
As the battery reaches a fully discharged state, sulfuric acid is held suspended in the absorbed glass mat, still maintaining contact along the entire length of the plates. There is no accumulation of acid at the bottom of the cell, so, as charge current is applied, the plates accept it along their entire length.
The combination of thin plates and AGM technology facilitates faster and more efficient charge transfer, resulting in reduced charging times and improved energy usage.
HAWKER® proprietary manufacturing techniques create plates with extremely fine crystalline structures, leading to:
● Reduced susceptibility to sulfation (a primary cause of battery failure)
● Enhanced resistance to grid corrosion
● Superior cyclic performance
● Extended service life in demanding applications
The HAWKER FLEX® TPPL battery line represents a significant leap forward in motive power technology. By leveraging thin, high-purity lead plates, we've dramatically increased the surface area available for electrochemical reactions within the battery. This innovative design results in:
● Enhanced Charge Acceptance: TPPL batteries can accept charge at a significantly faster rate than traditional flooded batteries, minimizing downtime and maximizing productivity.
● Higher Power Density: Delivering more power from a smaller footprint, TPPL batteries enable increased efficiency and performance, especially in demanding applications.
● Consistent Performance: TPPL technology provides reliable and consistent power output throughout the discharge cycle for optimal equipment operation, even under heavy loads.
● Extended Lifecycle: The robust design and optimized electrochemistry of TPPL batteries allow them to live and perform much longer. That means you don’t have to replace them as often, lowering the total cost of ownership.
Of course, TPPL batteries aren’t just powerful; they’re also designed with sustainability in mind. The sealed, maintenance-free construction eliminates the need for watering, reducing labor costs and minimizing the risk of acid spills. This contributes to a safer work environment and a lower environmental impact.
Traditional flooded lead-acid batteries have served the industry well, but their limitations are becoming apparent. They must have routine maintenance, require longer charging times, and pose environmental risks.
Lithium-ion, while offering high energy density and fast charging, comes with a significant price tag and potential ethical concerns regarding sourcing and end-of-life management.
HAWKER® TPPL technology offers performance comparable to lithium-ion at a fraction of the cost. With lithium power at a flooded lead-acid price point, customers are provided with a high-performance solution that aligns with their budget.
| PERFORMANCE METRIC | HAWKER® TPPL | TRADITIONAL FLOODED |
| Cycle Life (80% DoD) | 1,200+ Cycles | 500-800 cycles |
| Charging Time (Full) | 2-4 hours | 8-10 hours |
| Self-Discharge Rate | <2% monthly | 5-15% monthly |
| Maintenance Requirements | Minimal to None | Regular watering, cleaning |
| Operating Temperature Range | -40°C to 50°C | -20°C to 45°C |
| Energy Density | 30-40% higher | Baseline |
| Environmental Impact | Reduced Lead Content | Higher Lead Content |
| PERFORMANCE METRIC | HAWKER® TPPL | LITHIUM-ION |
| Initial Invenstment | Moderate | High |
| Safety Profile | Very High | Requires battery management system (BMS) for safety |
| Recycling Infrastructure | Well-established, leveraging methods for traditional lead-acid batteries | Limited / developing |
| Raw material sustainability | High recyclability - 99% | Limited rare earth elements |
| Weight | Heavier | Lighter |
| Lifecycle Cost | Excellent value | Higher upfront cost |
For dealers, representing HAWKER® TPPL battery technology offers compelling advantages that directly impact customer satisfaction and business growth. Partnering with HAWKER® provides numerous advantages, including:
● Maximize Customer Uptime: Consistent power delivery and reduced downtime keep your customers' operations running smoothly, minimizing disruptions and maximizing productivity.
● Enhance Your Reputation: Offer a premium battery solution that delivers exceptional performance and reliability, building trust and loyalty with your customers.
● Increase Profitability: The cost-effectiveness and extended lifespan of TPPL contribute to a stronger bottom line for both you and your customers.
● Demonstrate Environmental Responsibility: Align your business with the growing demand for sustainable solutions, attracting environmentally conscious customers.
● Versatility Across Applications: As a TPPL company with extensive experience, HAWKER® has developed solutions for diverse operational environments, including high-cycle operations where conventional batteries fail prematurely.
While batteries may look similar from the outside, the HAWKER FLEX® TPPL battery technology is changing the way motive power operates. By understanding and communicating the science, performance advantages, and business benefits of Thin Plate Pure Lead (TPPL) technology, dealers can provide customers with a truly superior power solution that delivers measurable advantages in performance, reliability, and value.
For dealers seeking to differentiate their offerings and provide customers with exceptional power solutions, HAWKER® TPPL technology offers a compelling combination of performance, longevity, and value that traditional batteries simply cannot match.
Visit our website today to explore the technical specifications and application data for HAWKER FLEX® TPPL battery technology. Contact us today to discover how our comprehensive range of motive power solutions can help you optimize your business and exceed your customers' expectations.
