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Battery Recycling Fact Sheet

Johnson Controls is the world’s leading manufacturer of lead-acid batteries, producing more than 120 million per year. Our commitment to world-class technology and manufacturing excellence is reflected in our global brands, including OPTIMA, VARTA, LTH and Heliar, as well as through the private labels and automotive customers we supply.

Johnson Controls is also the global leader in closed-loop, lead-acid battery recycling. Our ongoing efforts have helped make lead-acid automotive batteries the most recycled consumer product in the United States. The following are industry and company facts related to the environmental impact of battery recycling.

Industry Facts

  • More than 97 percent of all lead-acid batteries are recycled. Compared to 49 percent of aluminum soft drink and beer cans, 45 percent of paper, 21 percent of glass containers and 38 percent of tires, lead-acid batteries top the list as the most highly recycled consumer product.
  • A new lead-acid battery contains 60 percent to 80 percent recycled lead and plastic.
  • The average lifespan of a car battery in the United States is between three and five years.
  • Non-recycled and disposed batteries can cause human sickness and skin burning and also have irreversible effects on the environment. When disposed batteries contaminate soil and water, the sulfuric acid, which doesn’t dissolve, can kill wildlife, vegetation and poison drinking water.
Related: Johnson Controls Battery Recycling Facts

  • Johnson Controls led the development of a reverse distribution collection infrastructure, or closed-loop recycling system using government approved processes designed with pollution control in mind.

  • Closed-loop recycling uses lead from old batteries to make new batteries, which are transported to customers all over the world. The cycle continues as lead from aftermarket batteries are used in new batteries.
  • Johnson Controls was the first manufacturer to produce a recycled battery case – made of polypropylene plastic from old cases.
  • Spent battery acid is converted to raw material for detergents and glass cleaners.
  • Johnson Controls is sharing its expertise in battery recycling around the world: 
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• In the summer of 2007, the company led a tour of Chinese government officials to its Mexico smelter plant to showcase the closed-loop recycling system. The tour is part of an ongoing relationship with the Chinese government to develop a similar system to help reduce pollution and related health risks.
• In Mexico, the company developed the LTH Distributor Network, a sustainable energy distribution system that has led to nearly 100 percent of car batteries returned and recycled.
• In December of 2007, the company has participated in an EPA workshop to discuss the closed-loop recycling process with organizations from across the world.

Battery recycling diagram

Johnson Controls Battery Recycling Process

  • Johnson Controls delivers fresh batteries to its more than 10,000 customer locations on a regular basis
  • On delivery, the company picks up spent batteries at each location.
  • The spent batteries are transported to a licensed smelter for recycling.
  • In the recycling process, the lead is separated from the polypropylene and fed into a furnace for smelting. 
  • The lead is returned to Johnson Controls for use in new batteries.
  • The polypropylene is washed and also recycled.
  • The acid is treated in the smelter's wastewater treatment plant and neutralized.
Recycling process graphic

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