In order to find a more convenient processing method and more suitable paste formula for making VRLA batteries, hydrogen peroxide solution and red lead (Pb3O4) have been used together during the paste preparation. The use of hydrogen peroxide solution to replace the conventional sulphuric acid solution can accelerate the oxidation of free lead in the paste and therefore reduce the time for the plate curing, while the addition of red lead can enhance the cell formation and improve the cell performance. Based on these two beneficial functions, a new process for making VRLA cells was proposed and investigated. Cells were assembled directly from freshly pasted plates without undergoing the conventional plate curing and drying process, and the battery formation that followed was successful. The new processing resulted in an increase in the production efficiency and a substantial reduction in production time and cost. The battery performance, in terms of both the initial discharge capacity and the cycle life, is also improved by the use of red lead.