The recycling of used lead–acid batteries is turning the corner to a greener, cleaner and more sustainable process. With the advent of new electrolysis-based processes coming from the USA and still under development within the EU, a new recycling era dawns. There is indeed the need for improvements in quality of secondary lead and for continued advancement in lead–acid battery technology to meet the ever-increasing demand for advanced electrochemical storage capacity. Aurelius has taken up a process that was originally pioneered by Dr Vasant Kumar et al. at Cambridge University. Industrialisation and commercialisation of the process is currently nine months into its development and, despite many hurdles, a full-scale production capacity plant is expected to be operating by Q1 2018. Key advantages of the recycling process have been previously disseminated at the ABC and other conferences. Aurelius in conjunction with Dr Kumar and his team have found ways to fine-tune the manufacture and quality of different grades of nanostructured lead oxide that is free from impurities and exhibits enhanced electrochemical performance, namely, up to 30% energy density gains on lead oxide made from even the purest of lead metal. The commercial viability of such greener and cleaner processes also faces challenges when compared to incumbent pyrometallurgical processes that, over years, have been well rehearsed, improved, and made very cost-efficient. Consequently, the presentation will show how Aurelius has endeavoured to ensure that its process is not only environmentally clean, but is also cheaper than processes presently employed in the market and yields a superior product for the manufacture of lead–acid batteries.