The document summarizes the manufacturing process of zinc-carbon dry cells. Key raw materials include zinc cans, manganese dioxide, carbon rods, and an electrolyte solution containing zinc chloride and mercury. The cathode mixture is produced by mixing manganese dioxide and acetylene black, then adding the electrolyte solution. The cell is assembled by inserting a separator, filling the cathode material, adding the carbon rod and sealing the can. A plastic gasket and negative terminal are fitted, then a positive terminal and metal jacket are added before final inspection. Strict safety and environmental practices are followed in manufacturing due to the hazardous materials.

1. Manufacturing of dry cell
Zinc-Carbon cell

2. Introduction
• A Dry cell is a type of electricity-producing
chemical cell, it as developed in 1886 by the
German scientist Carl Gassner.
• A common dry cell is the zinc-carbon cell, it is
also called as Leclanche cell, with nominal
voltage of 1.5 volts, the same as the alkaline
cell (since both use the same zinc-manganese
dioxide combination)

3. • Zinc-carbon cell made with manganese
dioxide and zinc as prime materials
• Zinc-carbon battery is one of the most widely
used batteries
• The battery is suitable for use in powerful
light, a flash light, a calculator, etc.

4. Raw materials
• Zinc can
• Separator & bottom paper
• Zinc chloride, Aluminium oxide, water & mercury
• Manganese
• Acetylene black
• PVC tube, gasket, & negative terminal
• Carbon rod (graphite rod)
• Vent washers, red rings and jackets

5. Cathode mixture production
• Manganese is added into a container along with a
reagent.
• Acetylene black is added. Acetylene black is the
chemical which offers conduction.
• The mixture weighing 150kg is mixed and spinned
for 4minutes.
• After 4 minutes, 19.25% ES is sprayed into the
mixture (150litres) and the wet mix is spinned for
3 minutes.
• From every batch of mix, a small sample is taken
for testing.

6. • ES station :
– The wet mixture of liquids sprayed onto the
chemicals are stored in the ES station.
– Zinc chloride, Aluminium oxide and water are
mixed with mercury to form an electrolytic
solution called as ES.
• The % of mercury varies depending on the
type of mix required.

7. Manufacturing process
ZINC CAN
• A zinc can functions as
both a container and
anode material.

8. Inserting a separator
• A separator and bottom
paper are inserted to
prevent short-circuit of a
positive and a negative
electrode.

9. Filling cathode material
• A mixture of
manganese dioxide,
electrolyte and others
are filled as a cathode
material.

10. Inserting a carbon rod
• A carbon rod for
collecting electricity is
inserted into the center
of a zinc can.

11. Sealing
• A plastic gasket for
sealing is fitted to
prevent leakage and
drying.

12. Fitting a negative
terminal and resin
• A negative terminal and
a washer are placed on
the bottom of zinc can
and shrinkwarpped by
resin tube.

13. Putting the positive
terminal and metal jacket
• A positive terminal and
a washer are placed on
the top of battery and
covered by a metal
jacket.

14. Inspection
• A battery is inspected
on its voltage, current
and appearance.

15. The batteries are packed
in export cartons
The batteries are
transported to the port
The batteries are shipped
to the customers all over
the world

16. ENVIRONMENTAL IMPACT
• Thousands of tons of zinc-carbon batteries are
discarded every year around the world & are
often not recycled.
• In the U.S, the state of california considers all
batteries as hazardous waste when discarded,
and banned the disposal of batteries with other
domestic waste.
• Zinc-carbon batteries must not be thrown in with
domestic waste, most stores that sell batteries
are required by law to accept old batteries for
recycling.

17. Safety aspects and ethics of
manufacturing
• Protective gloves must be worn during the
operation
• Mask must be worn in the area of cathode
mixture department
• Safety shoes must be worn in the production
plant
• Lab coats must be worn in the inspection area
• Apron must be worn in the production plant

18. THANK YOU