ASSA ABLOY gives emergency backup batteries a second life

How Intercel helped ASSA ABLOY Entrance Systems extend battery life through testing and reuse, without compromising on safety.

Automatic doors are designed to operate reliably for many years. But what happens when their emergency backup batteries are replaced long before the doors reach the end of their service life?

ASSA ABLOY Entrance Systems wanted to find a more sustainable approach to its emergency backup batteries, ideally extending their lifespan to match that of the doors themselves. In response, Intercel developed a testing process to assess used batteries and determine which ones could safely be reused.

The results demonstrate the potential: more than 90% of the 1,798 batteries tested met the requirements for reuse.

The challenge: extending battery life without compromising safety

ASSA ABLOY Entrance Systems provides automatic entrance solutions where reliability is essential. Emergency backup batteries play an important role in ensuring that automatic doors can perform their required function during emergencies.

While an automatic door has an average lifespan of approximately 14 years, its backup batteries were traditionally replaced every two to three years.

This raised an important question: were all these batteries actually reaching the end of their useful life?

“We were looking for a battery solution that could last as long as the door itself,” explains Patrick de Wit, Director Service Sales at ASSA ABLOY Entrance Systems.

The company wanted to reduce unnecessary battery replacements while maintaining the strict safety and quality requirements associated with automatic entrance systems.

The solution: testing before replacing

Initially, switching to lithium batteries was considered. However, the existing charging infrastructure made this an unsuitable option from a safety perspective.

Instead, Intercel and ASSA ABLOY developed an alternative approach: rather than automatically replacing batteries based on age, assess their actual condition.

Intercel developed a dedicated testing protocol to determine whether used backup batteries were still suitable for operation.

The process involves collecting the batteries, measuring their condition, discharging and recharging them, and evaluating their performance against defined requirements.

Each battery is assessed individually. Only batteries that pass the tests are approved for reuse, accompanied by a test report and certificate.

This allows ASSA ABLOY to make informed decisions about battery replacement based on measured performance rather than age alone.

The results:
over 90% approved for reuse

The initial testing programme delivered significant results.

• 1,798 batteries tested
• 1,630 batteries approved for reuse
• 90.7% approval rate

Even batteries more than four years old were found to meet the requirements for reuse.

These findings show that many batteries previously destined for disposal may still have useful service life remaining.

By identifying these batteries, ASSA ABLOY can reduce unnecessary replacements and make better use of existing materials.

Safety remains the priority

For automatic entrance systems, battery reliability is not optional. Emergency backup power must be available when needed, particularly where doors serve as emergency exits.

That is why reuse is only possible when a battery’s condition and performance can be verified.

Through individual testing, documented results and certification, Intercel helps ASSA ABLOY assess whether each battery meets the required standards before being returned to service.

The approach combines circularity with a controlled process focused on safety and reliability.

A partnership with potential for further impact

The collaboration between ASSA ABLOY and Intercel began approximately two years ago, partly driven by ASSA ABLOY’s preference for working with local partners.

The first approved batteries are now being returned to service at customer locations.

The initiative supports ASSA ABLOY’s wider sustainability strategy, which focuses on people, products and processes. In the future, the company also sees opportunities to involve people who face barriers to employment in further developing the process.

“We are starting on a relatively small scale, but imagine the impact if we could apply this on a much larger scale,” says Patrick de Wit.

For Intercel, the project demonstrates how battery expertise can contribute to circular solutions beyond supplying new products. By testing and evaluating existing batteries, valuable materials can remain in use for longer.

Looking to extend the useful life of your industrial or backup batteries?

Intercel helps businesses find reliable battery solutions, from selecting new systems to exploring opportunities for testing and reuse. Contact our specialists to discuss the possibilities for your application.