Vehicle Count Down? Get Ready for a Spike in Battery Replacements.

by | Apr 28, 2020 | Battery Tips, Servicing and Repairs | 0 comments

Get ready for a spike in battery replacements.

Key Takeaways

  • Extended parking and short-trip driving during COVID depleted millions of batteries — a predictable replacement surge was already building in the fleet.
  • Lead-acid batteries left at or below 80% state of charge sustain irreversible sulfation damage, permanently reducing their useful lifespan.
  • Short trips (5–10 minutes) can’t return enough charge to offset the energy drawn at cold-engine startup, compounding degradation over time.
  • Shops that test every incoming vehicle — not just symptom vehicles — will capture the most replacement revenue as service counts recover.
  • Professional battery testers enable high-throughput testing so volume increases don’t create bottlenecks at the service drive.
The COVID-19 global pandemic has far reaching impacts on almost every aspect of life, including the practice of routine vehicle maintenance.  Social distancing, working from home, and mandated shutdowns all led to a steep decline in the amount of driving the average person does in a week.  As such, vehicle counts for routine service and preventative maintenance are down year over year across the globe, and the batteries are discharging every day they sit idle.   Additionally, the new driving behavior is hard on the battery.  Instead of driving 20-40 minutes to and from work every day, consumers are driving 5-10 minutes to and from the grocery store once a week.  Short and infrequent driving behavior can leave batteries in various states of discharge. In fact, our studies show that leaving lead acid batteries in a state of discharge (80% or lower state of charge) can lead to irreversible damage to the battery’s useful lifespan.  As the world starts to emerge from lockdowns, consumers will begin driving more. However, an abnormally large amount of these vehicles will be carrying batteries in compromised states of charge and health.  Our statistical modeling shows a battery replacement spike will likely occur due to the significant decline in preventative maintenance testing and the accumulation of bad batteries.   Therefore, as your vehicle counts start to rise again, test every battery that you see.  As a result, you will experience a spike in battery sales. More importantly, you will help your customers avoid a no-start situation. Shops equipped with professional battery testers are positioned to handle high-volume testing efficiently — and capture the revenue that comes with it.   If you would like to better understand how this trend may impact you, please contact your Midtronics account manager. 

Frequently Asked Questions

Why does short-trip driving damage a car battery?

A cold-engine start draws significant current from the battery. Fully recovering that energy through the alternator requires roughly 20–40 minutes of driving. Trips shorter than that leave the battery in a partial state of charge — and repeated partial charge cycles cause sulfation and stratification in lead-acid cells, permanently degrading capacity.

At what state of charge does a lead-acid battery start to sustain permanent damage?

Midtronics’ research shows that lead-acid batteries left at 80% state of charge or below for extended periods begin accumulating irreversible sulfation damage. The longer the battery sits undercharged, the more capacity is permanently lost — which is why testing and conditioning vehicles coming out of storage matters.

How should service shops prepare for a battery replacement spike?

The single most effective step is procedural: test every battery that comes through the door, regardless of the customer’s stated reason for the visit. Shops should ensure they have adequate tester inventory, trained advisors who can explain results, and enough battery stock on hand to meet elevated demand. The MDX-600 Series is built for exactly this kind of high-throughput environment.

Should technicians test vehicles that show no battery symptoms?

Yes — especially after a period of reduced driving. Batteries in compromised states of health often show no obvious symptoms until they fail completely. Waiting for a slow crank or a no-start means missing the revenue opportunity and the chance to protect the customer from a roadside breakdown.

How do industry data sources help shops forecast battery replacement demand?

The Battery Council International (BCI) publishes annual reports on battery shipments and replacement trends. Tracking BCI data alongside your own service metrics helps shops plan battery inventory during periods of elevated replacement activity — like the post-pandemic demand surge.

Which Midtronics testers handle high-volume battery testing best?

The MDX-600 Series delivers fast, accurate conductance-based testing with clear pass/fail results — ideal for dealerships and independent shops with high vehicle counts. For fleets and heavy-duty commercial vehicles, the DSS-5000 HD handles the demands of larger batteries. Both are built for consistency under pressure.