Johnson Controls, which has been manufacturing AGM batteries in Europe since 2002, produces more than 3 million VARTA Start-Stop Plus AGM batteries annually to supply the rapidly growing Start-Stop market. The company has started producing AGM batteries for the United States at its facility in St. Joseph’s, Mo., and will launch manufacturing later this year at its newly expanded facility near Toledo, Ohio.

We’re installing approximately 6 million in AGM annual capacity for the US market. Our estimates suggest that up to 40% of new cars being built the United States by 2016 could be Start-Stop vehicles requiring AGM batteries, in addition to the growing number of conventional vehicles that require a more robust battery.

—Mike Carr, vice president and general manager North America for Johnson Controls Power Solutions

Because some Start-Stop vehicles require special processes to replace and reset the battery and system, Johnson Controls developed its VARTA Start-Stop Service Program (VSSP) in Europe, and plans to bring a similar program to the United States. The VSSP program provides workshops with the necessary training, information and equipment to allow technicians to test the battery, examine relevant control modules, delete error codes, reset the memory and read replacement instructions as they go.

Johnson Controls’ AGM batteries are engineered to extend the life and improve performance of the battery. This includes a reinforced plastic case, a venting system that better maintains the seal over life, increased charge acceptance on the negative grid, and higher density material on the positive grid to improve cycling. The batteries also feature the company’s patented PowerFrame grid technology, which reduces premature failure and resists corrosion up to 66% more effectively than other grid designs.

Its design provides superior starting performance over the life of the battery with up to 70% better electrical flow than other grid technologies, according to the company. And, the PowerFrame grid manufacturing process uses 20% less energy and releases 20% fewer greenhouse gas emissions than other manufacturing methods.

AGM batteries to meet European sizes (H6, H7, H8) are available today. Group 31 commercial truck batteries will launch in July, with US-focused car and light truck group sizes 24F, 34, 65 and 78 slated for late summer and early fall.