Lead Oxide (PbO) is the main material used for the preparation of the active material for the positive and negative electrodes in the lead acid battery where the electrochemical reaction that provides the electrical energy of the battery takes place. The particle size distribution and surface area characteristics of the lead oxide play a major role in the electrical performance of the completed battery. The two most commonly used processes to manufacture PbO in the lead acid battery industry are the Barton pot and the Ball mill processes. These two processes produce oxides that differ in particle size distribution, particle shape and surface area. It is generally accepted that the Ball mill process produces an oxide with a smaller mean particle size with a higher surface area and better initial electrical performance than the Barton pot process to the detriment of an initial higher capital and running cost. The study showed that it is possible to improve the surface area and particle size distribution characteristics of Barton pot oxide, by subsequently hammer milling the oxide particles before the paste manufacturing process. The results showed that there was an initial reduction in the particle size with an increase in the surface area. This increased the electrochemical performance in terms of the high rate discharge. However, further hammering of the oxide reduced the average particle size only slightly with little change in the surface area and a reduction in the electrochemical performance. The study showed that an improvement in Barton pot oxide can be achieved with a hammering of the oxide in order to obtain a uniform particle size with improved surface area and an improved high rate performance of the electrochemical cells made with such an oxide. As a comparison, the particle size and surface area characteristics of Ball mill lead oxide subjected to the hammer milling process was also studied. The results showed a similar effect to the Barton pot oxide on the particle size distribution. However, there was no appreciable change in the surface area due to the hammer milling process.