Alexander Battery Technologies, the specialist in customisable lithium-ion and NiMH battery packs and chargers, has achieved yet another highly successful year, backed by substantial investment in both people and capacities as demand for environmentally friendly solutions across all sectors increases.
The company has earned a formidable reputation not only for its outstanding battery products but also for supporting its customers with critical related services such as supply-chain resilience and buffer stock programmes, end-of-life management, and rapid prototyping.
ABT flexibility and speed of response were evident during the pandemic, when its revenue increased tenfold through its work for the medical sector, and production expanded successfully from a single factory to two additional sites within a period of three months.
We interviewed CEO Mark Rutherford over a year ago when ABT was enjoying steep growth. In 2023, this trajectory continued as the company was able to win more customers and ventured into new markets.
“Growth has always been on our agenda,” says Rutherford. “In an environment where batteries are a growing topic, it’s crucial to persuade customers that we have the ability to scale up as a reliable supplier they can always count on in the long term.”
“We have demonstrated that we have the facilities, we have the professionalism, we have the staff. I believe this is what makes us stand out,” he says. “We are also a forward-thinking business, we are pro-active, not reactive. That also gives us a competitive edge.”
Investing in the future
This proactive attitude has driven investment in both technology and people. Earlier this year, Alexander Battery Technologies became the first company in the world to install an EV Flex laser welder underlining its commitment to leading-edge production technology, making the company the most technologically sophisticated manufacturer of embedded battery packs on a global scale.
The EV Flex laser welder, an IPG Photonics product, uses machine vision technology and configurable optics to produce micrometre-accurate welds between the terminals on a battery cell and busbar. This will enable ABT to achieve quality standards matching those specified by premium electric vehicle manufacturers.
“The products and the sectors that we want to break into require us to have that level of machinery, and this state-of-the-art technology will further increase our competitiveness,” says Rutherford. “We could get much cheaper technology, but we plan for the future. The EV Flex can deal with different types of welding applications for different sectors, so we won’t have to keep reinvesting in more machines.”
The new laser machine is only part of Alexander Battery Technologies asset expansion. The company last year opened its brand-new Battery Technology Centre in Peterlee, which includes 12 specialist state-of-the-art R&D labs capable to support new developments of up to 800V and over 100kWh when needed. The 1,850m2 centre complements the company’s existing facilities, which include a battery assembly unit, a large warehouse for holding buffer stocks of components for custom packs, a design engineering laboratory, and staff training suites.
Rutherford explains that the Battery Technology Centre, worth £1.5 million, will add advanced engineering and service capabilities as the company begins its first projects developing and prototyping for e-mobility customers. “The Centre provides us with additional manufacturing space, which will allow us to manufacture large, high-voltage battery packs, and if needed we could ramp up production from several hundred to thousands.”
Talent development
Rutherford points out that the speed at which the battery market is developing creates a significant skills gap, particularly in electronics engineering. To this end, ABT has expanded its apprenticeship programme with a view to having at least one apprentice in each department by the end of the year. “We are determined to support young people and show them the great opportunities that manufacturing offers.”
“By offering permanent employment opportunities post-apprenticeship, we are not only investing in the professional development of young, local people but also ensuring a sustainable talent pipeline for the future,” he says. “This is very important for me personally. When I was at school, no one told me that I could have a great career in manufacturing and become a CEO. I want schools and young people to know that manufacturing is an attractive option.”
He further affirms that Alexander Battery Technologies culture, based on honesty and transparency, is a reflection of the company’s striving to ensure that staff feels valued and supported on their career path. The company is committed to being an equal opportunity employer and diversity is embedded in its culture. Unusual for the heavily male dominated UK manufacturing sector, about 50% of ABT employees are women across all levels of the business.
“My business partner and CFO Claire Brymer is herself a great example of a success story. She started in ABT as an apprentice 25 years ago at the age of 16 and moved all the way up to becoming a co-owner and a board member,” considers Rutherford.
The right partnership
Given its successful development over the last few years, the company has recently expanded its sales & marketing team from 3 to 14 people, of which 3 employees are in DACH. A sales office has been established in Frankfurt, Germany, currently employing four people but Rutherford explains that the premises are large enough to increase staff numbers to 35 if demand grows as expected. Potential manufacturing facility in Europe is also in the pipeline in the longer term.
“Being close to our European customers will not only improve relationships but also reduce our environmental footprint. As the battery packs are getting bigger and heavier, shortening the shipping distance will have an impact. Promoting our green practices with regard to the product lifecycle is an important factor as we strive to become carbon-neutral by 2030.”
In concluding, he affirms that Alexander Battery Technologies is ready to meet new requirements from both existing and new customers, looking at new sectors such as e-motorbikes, off-road, commercial, and marine vehicles as well as aviation. However, it is not just about driving profits,” he says. “It is about selecting the right partner and establishing a relationship on a long-term basis.”
