German tier 1 supplier Continental’s Gurgaon plant has attained a new production milestone of producing 10 million Electronic Brake Systems (EBS) and 100 million Wheel Speed Sensors (WSS), two components integral to the safety of a vehicle. 

The EBS portfolio comprises Electronic Stability Control (ESC) for passenger cars and Anti-lock Brake Systems (ABS) for both, passenger cars and two-wheelers. It provides directional stability and steerability of the vehicle whereas, ABS aims to avoid locking of the wheels and keeps the vehicle steerable during braking. Additionally, the signals from the WSS are required for control systems like Anti-lock Braking System (ABS) and Electronic Stability Control (ESC).

The company states that over 1.3 million people loose their lives in road accidents worldwide every year and more than 50 million are injured. In India, 53 accidents and 19 deaths occur every hour, or an average of 1,264 accidents and 42 deaths daily due to road crashes, according to a Ministry of Road Transport and Highways report in 2023. To enhance road safety in the country, ABS technology was made mandatory in 2019, followed by a proposal for ESC in 2022 by the government.  

Sukhdeep Sandhu, Head of Safety and Motion, Continental Automotive India said, “Safety is non-negotiable. At Continental, we have consistently brought relevant technologies to the market for our customers, helping make vehicles and thereby our roads safer. Our expertise in active and passive safety systems is a key driver in reducing the number of traffic-related fatalities, injuries, and road accidents”.

“Localisation is at the core of company’s strategy in India. Supported by legislations which have played a huge role in ensuring vehicular safety, we have been able to localise both production and R&D, ensuring greater value to our customers in the market. Customers in India are proactive in their adoption approach towards safety technologies”, he added.

Continental’s ‘Vision Zero’ is focussing on ensuring zero road fatalities, injuries and crashes, through technologies, components and systems and ongoing innovations.

The tier 1 supplier is also one of the largest manufacturers of WSS in India. Apart from catering to leading OEMs in India, these components are also exported to other Asian and European regions.

Anudeep Garg, Head of the Gurgaon plant, Continental Automotive India said, “We are proud to achieve this milestone and continue to focus on localisation. As a Tier 1 supplier, we follow global manufacturing standards and have adopted several advanced technologies to create a digital shopfloor. Additionally, industry 4.0 technologies enable us to not only maintain product quality and enhance efficiency but also to effectively streamline our supply chain. We aim to increase the manufacturing capacity of EBS and WSS in double-digit percentages in the next three years for both passenger vehicles as well two-wheelers.” 

Continental’s ‘in the market, for the market’ approach has seen its entire value chain from R&D to design and production being localised. This way Continental is focusing on enabling easy access to safety products by adapting globally proven technologies to suit the local market. Wide-scale production offers economy of scale and ensures cost advantage, thereby contributing to increased democratization of safety features in vehicles across segments in India.

It was in 2016, when Continental set up assembly lines in Gurugram for Antilock Brake Systems (ABS) and Electronic Stability Control (ESC) systems for two-wheelers and passenger cars. In 2018, it commenced production for ABS and ESC Electronic Control Units (ECU) at its Bengaluru plant. In the subsequent year, the company achieved the production milestone of one million ABS and ESC ECUs at its Bengaluru plant, and in 2020, reached a milestone of 50 Million Wheel Speed Sensors (WSS) at its Manesar plant. Additionally, Continental entered into a joint venture with Japanese firm Nisshinbo Holdings in 2022, to localise machining for valve blocks for Electronic Brake Systems (EBS) in India. 

The narrower, bigger diameter tyres of electric vehicles are encouraging innovation around them. Supporting lower rolling resistance, the tyres are pushing suppliers and OEMs to explore new technological innovations. A leading German auto supplier for example has developed a ‘mechanical’ technology to ensure superior manoeuvring with near 180 degrees turn of the steered wheels. 
This is a development that could be applied to ICE rear-wheel drive vehicles as well. Even, light-duty commercial vehicles such as the Tata Ace/1000 or the Switch Iev3/Iev4 that are aimed at the last mile delivery segment were backing up into a tight parking spot or navigating through a narrow lane is part of the job. 
As designers and engineers toy with the idea of larger wheel wells and the ability of the steered – front – wheels to turn as much as 180 degrees, the use of narrower, bigger diameter tyres with low rolling resistance in electric vehicles is spurring yet another round of innovation, albeit as a part of the entire platform architecture that is rather software driven and subject to much virtual development in the interest of ‘time-to-market’ and a differentiated user experience. 
With over 14 million small electric vehicles sold in 2023 the world over, the push has been to develop tyres that enhance operation and performance. Provide a typical ‘family’ car the ability to transform into a sports car given the wave of high torque available from the word ‘go’ in an electric vehicle. 
With electric vehicle sales poised to increase 17.5 percent year-on-year globally to bridge 41.2 million units in 2029, electric vehicle tyres are expected to facilitate a further drop in rolling resistance while employing sustainable raw materials, technologies and manufacturing processes. 
A sustainable EV tire design should consider the whole lifecycle of the product. Tires can be composed of well over 100 different raw materials. These are mixed and the rubber compounds are machined resulting is several components of the tire construction. EV tires are expected to be stronger and lighter, with less rolling resistance due to its importance in CO2 emissions and fuel consumption. 
A key challenge being the development of tyre formulations for electric vehicles with the tread compound that is more resistant to abrasion, it is the instant torque availability that is necessitating tyres that may look like ICE vehicle tyres but are quite different in the way they handle traction and aid a longer drive range. There is the issue of kerb weight as well, not to overlook the new environmental pressures for durability and abrasion resistance. 
Interestingly, new opportunities are being created on the vehicle engineering and dynamics side as well as on the side of electric vehicle tyre development and manufacture. 
Starting with materials that are broadly classified as ‘renewable’ (can be sustained on time) and as ‘recycled’ (re-used and made from recovered end-of-life tyres), it is the tandem mixers that are producing more homogeneous rubber compounds, including tread compounds that employ optimised silica fillers.
Tyres for electric vehicles are demanding the use of triple or quadruple extruders for treads and sidewalls as per the vehicle weight, application and dynamics. Roller head or roller die units are also being used to produce inner liners as a single or multilayer sheet
In terms of textile coating of steel cord components in e-vehicle tyres, four-roll and Z-type calendars are used. Also, full tyre assembly machines that can produce tyres to tighter tolerances, higher specs such as superior uniformity and sans operator invention. 
With electric vehicle tyres and ICE vehicle tyres being tested and validated differently primarily because of the higher load bearing capacity and low rolling resistance, electric vehicle tyres are made up of a different (softer) rubber compound than regular tyres with an eye on less noise, mentioned a testing expert at an OEM that is increasingly producing electric vehicles in India. 
Pointing at an electric passenger vehicle the company launched in India recently, he averred, “Softer compounds are used to ensure less rolling noise and better transmission of torque from the motors to the road.” 
With finer tolerances in need, optical machine vision systems for end-of-line quality inspections, including new technologies such as X-rays to check steel belts, cords and bead reinforcement are increasingly used. 
They are used to check for air bubbles in inner liners as well. Advances in tyre design and manufacture include new developments in simulation software to model the performance of new designs quickly. This is without material input cots. 
AI is being increasingly used to ensure superior analysis. AI is also used to automate manufacturing process as part of Industry 4.0 workflows. 

Hyundai Motor India (HMIL), one of India’s leading passenger vehicles manufacturers, has been taking huge strides to cut down on its carbon footprint both on-road and off-road.

Taking advantage of the country's robust railway network, Hyundai Motor India shipped 26 percent of its total domestic wholesale vehicles through rail freight in 2024.

This translates to a total of 1,56,724 units transported through Indian Railways, cutting down on almost 18,352 tonnes of CO2 emissions.

Interestingly, the company claims that 100 percent of its dispatches to North East India were utilised rail freight. Furthermore, between 2021 and 2024, Hyundai Motor India transported 5,37,499 vehicles using the rail route, which led to a prevention of 63,452 tonnes of CO2 emissions versus road freight.

Tarun Garg, Whole-time Director and Chief Operating Officer – Hyundai Motor India, said, “At HMIL, we have been relentless in our pursuit of promoting sustainability in all facets of our operations, be it manufacturing, dispatches, sales or after sales support. By utilising Indian Railways’ extensive rail-network for delivering Hyundai vehicles from our plant in Sriperumbudur, Chennai, to multiple locations across India. As the Government of India continues to upgrade the rail infrastructure with dedicated freight corridors and modern and energy efficient rolling stock ensuring faster movement of goods, HMIL remains committed to utilising rail freight to optimise its logistic operations, leading to long-term reduction in emissions.”

Leading construction equipment manufacturer SANY India has inaugurated a new factory expansion at its 90-acre manufacturing facility in Pune, representing a major step forward for localised manufacturing and increased production capacity in India.

The new facility has a strong fabrication capacity of over 100,000 metric tonnes annually in addition to an annual production capacity of over 14,000 units. These skills put SANY India in a position to effectively meet the growing needs of the mining, energy and construction industries both domestically and internationally while preserving operational precision and flexibility. This reaffirms SANY's dedication to the Indian market and to making India a worldwide centre for sourcing.

Emphasising the strategic importance of the expanded facility, Xiang Wenbo, Chairman, SANY Group, said, "This new factory represents a significant step forward in our commitment to delivering world-class products with utmost precision. By incorporating the latest manufacturing technologies, we are positioning ourselves to meet both the challenges of today and the demands of tomorrow." India is a key operational base for SANY's international operations and a pillar of the company's worldwide strategy, he said, underscoring the country's long-term potential.

Deepak Garg, Vice Chairman & Managing Director, SANY India, said, "The inauguration of our new factory expansion represents a significant leap in SANY India's manufacturing capabilities. This facility also supports our commitment to the Prime Minister’s vision of ‘Make in India’ by enhancing exports to key markets and driving increased localisation in our manufacturing processes. These efforts not only boost India’s manufacturing prowess but also strengthen our role in the nation's infrastructure development story."

Pure EV, an electric two-wheeler start-up, has integrated 500 KWh of Energy Storage Solutions (ESS) and 125 KW of solar system with DG and grid at its facility in Telangana, to cut down on its carbon footprint.

The start-up claims it has been able to reduce 60 percent of power bill and 65 percent in DG fuel bills compared to FY2023. The 500 KWh installed capacity fully consists of refurbished batteries that was repurposed from its customers who exchanged their old batteries for the Pure EV’s 5th generation batteries.

Dr Nishanth Dongari, Founder & MD, Pure EV, said, “We are happy that our actions stay true to our genesis of Power Using Renewable Energy (PURE), which not only helps us reduce our environmental impact but also significantly cut energy costs. By harnessing the power of solar energy in combination with cutting-edge energy storage technology, we are making powerful strides towards a more sustainable future. This approach not only reduces our reliance on non-renewable resources but also enhances our operational efficiency, ensuring that we are driving both environmental and economic benefits. As we continue to innovate and integrate these green technologies into our business model, we are reinforcing our commitment to sustainability and shaping a cleaner, more energy-efficient tomorrow."

Going forward, Pure EV aims to add 125 KW solar system and 500 KWh ESS by 2026.