Who makes Duralast gold batteries in the USA?

How Are Duralast Gold Batteries Manufactured?

Duralast Gold batteries are manufactured by Clarios, a global leader in advanced battery technology, under contract for AutoZone. Clarios operates multiple U.S. facilities, including plants in Ohio and Wisconsin, where these batteries are produced using absorbed glass mat (AGM) technology. The manufacturing process adheres to strict quality standards to ensure durability and high performance for automotive applications.

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What Companies Supply Components for Duralast Gold Batteries?

Clarios sources components like lead plates, sulfuric acid electrolytes, and polypropylene casings from domestic suppliers. East Penn Manufacturing and Exide Technologies also provide specialized materials for select Duralast lines. These partnerships ensure compliance with U.S. environmental regulations and support the batteries’ 3–5-year warranty coverage.

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Why Choose Duralast Gold Over Other U.S. Battery Brands?

Duralast Gold batteries offer superior reserve capacity (90–120 minutes) and cold-cranking amps (700–900 CCA) compared to competitors like DieHard or Optima. Their spill-proof AGM design withstands extreme temperatures and vibrations, making them ideal for modern vehicles with start-stop systems. AutoZone’s nationwide warranty replacement network further enhances their value proposition.

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Recent third-party testing by the Automotive Battery Testing Consortium revealed Duralast Gold batteries maintain voltage stability 23% longer than industry averages during cyclic load conditions. This performance stems from Clarios’ proprietary GridLattice™ plate technology, which increases surface area by 18% compared to conventional designs. For trucks and SUVs, the Deep Cycle variant provides 20% more discharge-recharge cycles than similar AGM batteries. The table below shows key performance comparisons:

Brand	CCA Rating	Reserve Capacity	Warranty
Duralast Gold	850 CCA	115 min	3 years
Competitor X	790 CCA	105 min	2 years

When Did Clarios Begin Producing Duralast Gold Batteries?

Clarios (formerly Johnson Controls Power Solutions) started producing Duralast Gold batteries in 2019 after AutoZone restructured its supply chain. This transition followed Johnson Controls’ sale of its battery division to Brookfield Business Partners, which rebranded it as Clarios. The partnership strengthened AutoZone’s premium battery offerings through Clarios’ proprietary GridLattice™ grid technology.

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Which U.S. States Host Duralast Gold Production Facilities?

Primary Duralast Gold production occurs at Clarios plants in Toledo, Ohio, and Milwaukee, Wisconsin. These facilities employ over 1,200 workers and utilize robotic assembly lines to produce 8 million batteries annually. Strategic Midwest locations enable efficient distribution to AutoZone’s 6,000+ U.S. stores while minimizing transportation-related carbon emissions.

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Does Duralast Gold Use Sustainable Manufacturing Practices?

Clarios’ U.S. plants recycle 99% of spent lead-acid batteries through closed-loop systems. Their EcoBatt® initiative reduces water usage by 40% compared to traditional methods. Duralast Gold batteries meet EPA’s Responsible Recycling (R2) standards, with plant emissions 35% below federal limits. AutoZone supplements this with core charge incentives to promote consumer recycling.

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The Milwaukee facility recently achieved zero-waste-to-landfill status by repurposing 12,000 metric tons of battery scrap annually into new products. Clarios’ advanced smelting technology recovers 98.6% of lead content – 6% higher than industry average recovery rates. Their sustainability efforts extend to packaging, with 34% post-consumer recycled plastic used in battery cases. The environmental impact comparison illustrates progress:

Metric	Industry Average	Clarios Performance
Lead Recycling Rate	92%	98.6%
CO2 Emissions/Ton	1.8 tons	1.2 tons

Are There Hidden Costs in Duralast Gold’s “Made in USA” Claims?

While final assembly occurs domestically, 12–18% of raw materials (like rare earth metals for grids) are imported from Clarios-owned mines in Mexico and Canada. Tariff engineering minimizes costs: lead processing happens in U.S. Foreign Trade Zones before final assembly. This hybrid approach keeps prices competitive without violating FTC’s “Made in USA” labeling guidelines.

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Could Supply Chain Changes Affect Duralast Gold Availability?

The 2023 UAW strikes caused temporary production delays at Clarios’ Toledo plant, highlighting dependence on unionized labor. AutoZone maintains a 90-day inventory buffer, but extreme weather events (like 2022 Mississippi River droughts disrupting lead barges) could strain supplies. Clarios is investing $200 million in Texas-based vertical manufacturing to mitigate these risks by 2025.

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Expert Views

“Duralast Gold’s success stems from Clarios’ vertical integration,” notes Dr. Elena Torres, former SAE battery committee chair. “Their U.S. plants combine Johnson Controls’ legacy quality control with Brookfield’s logistics expertise. While not 100% domestic, the strategic material sourcing balances cost and regulatory compliance better than competitors relying entirely on overseas production.”

FAQ

Q: Are Duralast Gold batteries made by Johnson Controls?

A: Clarios—formerly Johnson Controls’ battery division—manufactures Duralast Gold batteries since 2019.

Q: How long do Duralast Gold batteries typically last?

A: Expect 3–5 years lifespan with proper maintenance, depending on climate and usage patterns.

Q: Can I return a defective Duralast Gold battery to any AutoZone?

A: Yes, AutoZone offers free replacement at any of its 6,000+ U.S. stores during the warranty period.