AVL is the world’s largest independent company for development, simulation and testing in the automotive industry and in other sectors. As a global technology leader, AVL provides concepts, solutions and methodologies in the fields of e-mobility ADAS and autonomous driving, vehicle integration, digitalisation, virtualisation, big data and much more.

In an interview with Sharad P Matade, Urs Gerspach, Executive Vice President of Test Systems and Global Operations, Instrumentation and Test Systems at AVL, shares his thoughts on the growth enablers and the company’s capabilities to cater to a wide range of demand in the automotive testing business.

What is the impact of the Covid pandemic on AVL’s testing business?

There is an impact, no doubt about it. The effect was much stronger last year; the customers constantly postponed their decisions about the orders of lab projects. However, this year, we are seeing a sudden improvement in the situation. In the first quarter of this year, we received massive orders of over 180 test systems for battery test labs. The situation is improving very fast, and the investments are being released by the OEMs. Until last year, the trends were not clear. Now we see a fast and strong growth of the passenger car industry towards electrification business. We are also witnessing the growing focus on fuel cells in the commercial truck segment. AVL is very well on track regarding its turnover and our margins for this year.

What is the reason for the increased demand of battery test labs?

In the past, many OEMs bought their battery cells from cell manufacturers like Panasonic, LG, CATL etc. and used these third party cells to build their own batteries. Several passenger car OEMs changed their strategy and decided to develop their own battery cells. Increased range, reduced charging time and lower costs are important key factors to convince customers to buy electric cars. Not just the development of the battery, but the combination of Battery, Inverter, E-Motor and Charging Infrastructure is important to develop a successful electric car. For this development, you need new test equipment such as battery cell cyclers, conditioning systems, climate chambers, automation and lab management software. The entire car is tested on High Voltage Powertrain Test Beds and Chassis Dynos where AVL has been the market leader for many years.

Europe is gearing up for Euro-7. What is it? How will it influence the testing business?

EU-7 will set stricter limits for CO2 and particle emissions. We expect PM10 (particulate matter with a size of 10 μm) will be introduced for Euro-7 and we have therefore developed measurement systems which can measure PM10.

It is also important to measure the CO2 emissions of combustion engines as precisely as possible. It is not just about compliance with environmental standards, but also about fuel consumption. We also deliver Portable Emission Measurement (PEM) systems for measuring emissions in real-time conditions on the street. While driving the car under real conditions, you might not execute a certified test run under predefined environmental conditions, therefore, other emissions will occur that need to be measured and analysed. AVL offers a wide range of in-vehicle measurement systems and software to determine what is actually coming out of the exhaust - in real driving conditions.

But there will also be a focus on non-exhaust emissions, particularly brake dust. Electric vehicles don’t emit exhaust emissions, but there is still brake and tyre dust. We have developed entire test systems to test real brakes under real-time conditions.

What would be the significant growth drivers in the traditional combustion engine business for AVL testing divisions?

As mentioned, the Euro-7 regulation will be one of the main drivers for AVL in the future. Besides all the other technologies like ADAS, every engine will be partly electrified either as a pure Hybrid, Plug In- or mild Hybrid. The technology of an Integrated Combustion Engine (ICE) can also be used to run with pure hydrogen. AVL is developing several engines for various customers that convert existing ICE technologies in new concepts.

We are also working on measurement technologies for synthetic fuel. AVL is working closely with Formula One teams as they will soon run their engines with synthetic fuels.

AVL has played a significant role in the development of the diesel engine in Europe. However, many OEMs are talking about discontinuing diesel engine vehicles in the near future. Do you see this as a challenge?

This trend will not have a great impact on our testing division. It will have a larger influence on the powertrain development division for diesel engines. If you take a look at the share of electrified cars in Europe - especially in Germany - they only account for 10 percent of the total vehicles; the remaining share of cars are still powered by combustion engines.

The combustion engine will still remain relevant for a while. However, increasingly in the form of a hybrid powertrain. AVL is therefore converting existing test beds for the car manufacturers so that they can be used to test hybrid vehicles. There are several customers who request pure electrical test benches. Some of our customers come to us with the requirement to completely convert existing combustion engine test fields to electrification test systems.

Between electric vehicles and hybrid vehicles, which one holds more promise in India in the near term and the long term?

I believe, in countries where the electricity network is not yet fully developed, hybrid cars will provide more flexibility, combining the possibility to run with fuel for an overland trip and electrified within the city.

In India, two-wheelers might have a faster increase in electrification similar to the development in China. ICE engines might keep dominating for a while, especially for the commercial vehicle. The introduction of pure battery electric vehicles mainly depends on how fast India is able to provide the necessary high-voltage charging infrastructure.

What about the AVL Tech Centre in India?

Our Tech Centre in India is one of our strongest Competence Centre for turnkey projects. AVL India is a very strong and reliable partner when it comes to planning of entire test fields including plant facilities. In the field of Powertrain Development, our India Tech Centre focuses on all three technologies – ICE, electrification and hybridisation – equally in all segments. AVL is an engineering company assisting customers with all types of mobility technologies. We recently got one of the first orders for fuel cell test systems from an Indian customer. So there is something exciting happening in our Tech Centre in India.

What about the revenues? How much does your testing division contribute to the whole company?

In 2020, the company generated a turnover of EUR 1.7 billion, of which 12 percent was invested in R&D activities. The testing division contributes with around 50 percent of the turnover.

What are the challenges in the business?

One of the biggest challenges is definitely to cover the growing bandwidth of technologies. A couple of years ago, we were only talking about ICE vehicles. Today, we are talking about ICE vehicles, hybrid vehicles, electric vehicles, batteries, ADAS and autonomous driving, digitalisation, cybersecurity and big data. AVL has built comprehensive competences to accelerate the vision of smart and connected mobility.

If you are an engineer, you have a wide range of technologies to specialise in. So one of the challenges is to find the right engineers to work on these different technologies.

What is the latest on safety by AVL?

One of the issues that is yet to gain the industry’s attention is fire safety in electric vehicles. AVL has been associated with fire marshals in Europe. Fire brigades realised an increase in accidents with Battery Electric Vehicles (BEV). Not only accidents but also burning BEVs in parking garages are a big challenge. These vehicles are very difficult to extinguish due to the chemistry of the lithium-ion battery.

AVL has developed a firefighting system which can extinguish a lithium-ion battery fire on the testbed or for fire brigade usage. It is a unique patented system that runs on liquids such as water or gases like nitrogen to extinguish battery fires. We conducted a couple of test series with hybrid batteries. A burning battery with 18 metres of flame height and temperatures of up to 1,500 degrees Celsius could be extinguished in one minute. (MT)

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German material manufacturer Covestro has partnered with automotive major BMW, tier 1 supplier FORVIA HELLA, and academic research institutions to launch KOLLEKT, a project focused on developing recyclable automotive lighting and electronic components.

Funded by the German Federal Ministry for Research, Technology and Space (BMFTR) with EUR 4.371 million under the CircularGlowUp framework, the three-year initiative runs from June 2026 to May 2029.

The consortium led by coordinator FORVIA HELLA, includes BMW, Covestro, Geba, SW Maschinenservice, Fraunhofer IEM, Fraunhofer UMSICHT, the University of Paderborn, Hamm-Lippstadt University of Applied Sciences and the Helmholtz-Zentrum Dresden-Rossendorf. The initiative addresses vehicle recyclability, resource consumption and end-of-life material recovery in light of the EU End-of-Life Vehicles regulation.

The project focuses on product design optimised for repair, reuse, remanufacturing and recycling. Covestro contributes its expertise in polycarbonate materials, including its Makrolon, Bayblend and Apec product lines, to evaluate recycling pathways and material properties from the initial design phase.

Monique Buch, Chief Commercial Officer, Covestro, said, “KOLLEKT is a prime example of how we create value together with our customers and partners — going beyond material supply to co-designing solutions from the very beginning. By aligning early across the value chain with BMW, FORVIA HELLA and other partners, we can embed circularity directly into product development. That is what true co-creation looks like—and how we turn sustainability ambitions into tangible outcomes.”

Technological developments within the project include an artificial intelligence-driven robotic dismantling unit. Utilising digital product twins and real-time data processing, the unit aims to enable automated, material-pure disassembly at an industrial scale.

The initiative builds on the predecessor project NALYSES, which concluded in 2026. Project outcomes are intended to support compliance with EU ELV recycling targets through 2032 and assist vehicle manufacturers in meeting post-consumer recycled content quotas.

Guido Naberfeld, Head of Sales and Market Development Mobility, Covestro, stated, “KOLLEKT is a concrete step toward closing the loop on high-performance polycarbonate in automotive applications. By combining Design for Circularity with advanced recycling technologies and digital traceability, we are demonstrating that sustainability and material performance are not a trade-off. This is how Covestro contributes to meeting the EU's ELV targets and helps the entire automotive value chain transition to a truly circular model.”

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Mumbai-headquartered automotive major Mahindra Group has announced the appointment of Shveta Arya as its new Group Chief Strategy Officer, effective 15 September 2026. Arya will also join the senior management team of Mahindra & Mahindra and serve on the Group Executive Board.

In her new role, Arya will oversee the Group Strategy Office across the organisation's portfolio of businesses to determine growth opportunities and value creation. She will report directly to Dr. Anish Shah, Group CEO & MD of Mahindra Group.

Dr. Anish Shah said, “We are pleased to welcome Shveta Arya as Group Chief Strategy Officer. Shveta brings over two decades of leadership experience across business and strategy, as well as management consulting across diverse sectors. Her experience in driving growth, shaping strategy and leading through change will be valuable as we work with our portfolio of businesses to drive growth and create long-term value across our portfolio of businesses. Her passion for constructive change and holistic progress also resonates strongly with Mahindra’s purpose. I wish her the very best in this key leadership role.”

She comes with over 23 years of experience across publicly listed multinational organisations and management consulting. Her background spans the automotive, travel, financial services and telecom sectors.

Most recently, Arya served as Managing Director of Cummins India, where she managed operations, growth strategy, talent and workplace culture. She was also the program sponsor for Cummins' initiative focused on women and girls in India. Prior to Cummins, she led Strategy and M&A at Thomas Cook India and held roles at Kearney and Infosys.

Arya holds a Master of Business Administration from the Indian Institute of Management Ahmedabad and a Bachelor of Engineering in Information Technology from Delhi University.

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Envalior India Pvt. Ltd. has launched a specialised training hub focused on electric vehicle technology at MM Polytechnic in Pune, marking a significant step in aligning vocational education with the demands of the burgeoning EV sector. The Envalior Centre of Excellence, a product of the company’s CSR initiatives in partnership with the BroadArks Foundation, is intended to serve as a practical workshop where students can transition from theoretical knowledge to applied technical competence.

The facility was formally inaugurated by Christopher Stillings, Vice President –R&D, in the presence of Krijn Dijkstra, Nileshkumar Kukalyekar, Uday Shetty, Susmita Mishra, Hema Rani, Sainath Vaidya and Aniket Nirwan of Envalior, MM Polytechnic leadership and other dignitaries. By embedding this centre within a technical campus, the programme seeks to immerse learners in the realities of EV maintenance and repair, covering not just mechanical functions but also the intricate electrical and software-driven systems that define modern vehicles.

With an annual capacity to reach roughly 250 learners, the centre will cater to students from ITI and polytechnic backgrounds across multiple engineering streams. The coursework is divided into two progressive phases, starting with a foundational module that introduces participants to basic EV architecture, battery safety and routine service procedures. An advanced tier follows, offering deeper instruction on battery management systems, thermal controls, high-voltage safety protocols, motor controllers and complex diagnostic methods.

Beyond traditional lectures, the training environment incorporates interactive lab sessions with real vehicle components, diagnostic tools and industry-relevant projects, ensuring that participants acquire both safety awareness and problem-solving agility. The overarching goal is to produce graduates who are not merely familiar with EV theory but are confident in executing hands-on repairs and system evaluations. Through this scalable framework, Envalior is actively working to narrow the skills gap in India’s automotive sector, creating a direct pipeline of capable talent for the evolving mobility landscape.

Nileshkumar Kukalyekar, Business Director – South Asia, Middle East & Africa, Envalior, said, “The transition to electric mobility is creating a fundamental shift in the skills expected from the automotive workforce. For us, this Centre of Excellence is about ensuring that technical education keeps pace with that change. By giving students the opportunity to work directly with EV systems, understand advanced diagnostics and build capabilities through structured, certified training, we are helping create a stronger bridge between what young technicians learn and what the industry will increasingly expect from them. We see this as an investment not only in individual careers but in the technical talent that will support India’s mobility transition in the years ahead.”

Christophe Stillings, Vice President – R&D, Envalior, said, "At Envalior, we believe the future of mobility depends on developing industry-ready talent today. Through the Centre of Excellence, students will gain hands-on exposure to EV technologies, helping bridge the gap between academic learning and real-world industry requirements. By bringing together academia and industry expertise, we aim to equip the next generation of engineers with the practical skills, confidence and innovation mindset needed to succeed in a rapidly evolving automotive landscape."

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Tier 1 automotive supplier Schaeffler India has appointed Amit Bhalerao as its Chief Operating Officer, effective 10 August 2026.

In his new role, Bhalerao will oversee the company's manufacturing operations across India. His responsibilities include directing manufacturing strategy, operational performance, digitalisation projects and capability development, as well as managing local production initiatives across the firm's plant network.

Bhalerao will join Schaeffler India's Executive Leadership Team, collaborating with divisional heads to manage the company's operational footprint.

Harsha Kadam, Managing Director and CEO, Schaeffler India, said, "India continues to be a strategic growth market for Schaeffler, and strengthening our manufacturing and operations capabilities is central to our journey as the leading Motion Technology Company. Amit brings extensive experience in leading complex manufacturing operations, driving operational excellence and building high-performing teams. His leadership will further enhance our manufacturing competitiveness, customer focus and innovation capabilities as we continue delivering greater value to our customers and stakeholders. We wish Amit the very best and many successes in his journey at Schaeffler in India."

Bhalerao comes with 23 years of management experience in manufacturing, operations, lean transformation, quality assurance and supply chain management. Before joining Schaeffler India, he held the positions of Managing Director and Vice-President of Operations at Kelvion India, where he managed operations, technology transfer and capacity expansion projects. He has also held leadership positions at Cummins, Eaton and Sterlite Technologies.

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