Aluminium Can Play A Pivotal Role In The Changing Face Of The Automotive Sector

Aluminium Can Play A Pivotal Role In The Changing Face Of The Automotive Sector
Ajay Kapur

Currently, India’s foundry market for automotive components is small (only 10 percent of total foundry market — 10 million of cast iron + aluminium) in comparison to USA’s foundry market, which is at 14 million tonnes per annum, of which 3.3 million is aluminium (24 percent). With an increasing focus on higher performance with better safety and lower emission, this gap is going to shrink in the coming years, anticipates Ajay Kapur, CEO – Aluminium & Power Business, Vedanta Aluminium.

“There is immense scope for Indian aluminium producers to tap into the emerging market in the automotive sector,” said Kapur. Vedanta Aluminium was the first in India to supply PFA (primary foundry alloy) to the domestic auto sector. Before, the launch of PFA by the company, India’s entire PFA demand was being met through imports, even though the country has the world’s second-largest aluminium production capacity. Looking at the potential of the auto market and its import dependency, the company decided to tap into the opportunity and develop indigenous capabilities at its state-of-the-art facilities in Jharsuguda and BALCO to meet that demand. Currently, the company has a PFA casting capacity of 240KT spread across its plants in Odisha and Chhattisgarh.

“Primary aluminium producers develop PFAs which are customised to suit the exact needs of automakers in terms of performance, strength, durability, etc. Significant R&D and technical expertise go into developing PFAs, resulting in excellent metal quality and outstanding castability, which makes these alloys the preferred choice for the automotive industry,” explained Kapur. PFAs are ideal for aluminium alloy wheels, cylinder heads and brakes. The company also anticipates that with an increased focus on reduction of vehicle weight with higher safety performance, automotive parts critical to safety will be made from PFA instead of cast iron to offer higher strength and nearly double absorption of crash energy. “Besides, aluminium PFAs will always have the added advantage of cost-saving on fuel and maintenance,” added Kapur.

Vedanta Aluminium has started steadily supplying PFAs to OEMs and ancillaries in wheel manufacturing in India. “Our proactive move to expand business on this front helped us on-board some of the most reputed equipment manufacturers and auto ancillaries as our clients, and we have received a very positive response from them. Encouraged by that, we will soon look to expand our alloy portfolio for supporting manufacturing of cylinder heads, ABS brakes and certain key applications where traditional materials can easily get substituted with aluminium alloy. We are also exploring prospects of long-term investments by auto ancillaries near our aluminium smelters so that they may leverage cost savings in terms of freight, re-melting and electricity,” said Kapur.

The company, according to him, is well-positioned to cater to the current and emerging needs of the Indian auto sector, offering a broad range of products that find usage across the automotive value chain – from casting to extrusion. “When choosing suppliers for alloys, automotive players should look for companies having high-quality casting facilities, sophisticated R&D facilities and technological prowess for developing customised high-performance alloys for their specific needs, and finally, having robust after-sales technical support; USPs that have earned us the trust of our clients,” he added.

Aluminium is the second most used metal in the world after steel, today, and, according to Kapur, it has the potential to become the most important commercial metal in the future. “Most developed countries have already designated aluminium as a core industry. Aluminium holds strategic importance for the economy as the metal of choice for all kinds of transportation, power, aerospace, defence, building and construction needs. So, given the role it plays in supporting the core sectors meet the Government’s ‘Make in India’ initiative, we expect its application to only expand with time,” said Kapur.

The metal’s usage in the transportation sector has been rapidly increasing as it offers an environment-friendly and cost-effective way to increase performance, boost fuel economy and reduce emissions while maintaining or improving safety and durability. Aluminium is substantially lighter than its counterparts, offering a significant reduction in weight, which has a direct impact on fuel consumption and carbon emissions.

The metal also has a higher strength-to-weight ratio compared to traditional materials that enable it to absorb twice the crash energy of mild steel, ensuring that vehicular performance enhancements do not come at the cost of safety. “Further, nearly 90 percent of all the aluminium used in a vehicle is recycled at the end of its lifecycle. The energy required to recycle aluminium is only five percent of the energy required to produce the metal. With all these advantages, aluminium can play a pivotal role in the changing face of the automotive sector,” said Kapur.

Aluminium alloys are used by the Indian auto industry majorly as alloy wheels. Around 95 percent of two-wheelers include aluminium, averaging at 7kg per bike, taking total consumption of aluminium alloy in this segment to 115KTPA (kilo tons per annum). Whereas, only 20 percent of four-wheelers use aluminium, majorly in high-end models, which max out at 40kg per car. “The crux of the matter is, in India, we are yet to explore more applications of aluminium in the automotive industry akin to our global peers. For example, in developed countries, around 21 PFAs are used in the automotive segment to achieve light-weighting in the form of various auto parts and components. In India, we majorly use PFAs only for manufacturing alloy wheels and to some extent, for cylinder heads. So, there is immense potential for usage of aluminium in other auto parts like engine, suspension, front end carrier, instrument panel support, rear frame, chassis and many more,” said Kapur.

Shortly, the company expands its alloy portfolio for supporting manufacturing of cylinder heads, ABS brakes and certain other applications where currently steel or iron is being used but can be substituted by suitable aluminium alloys to provide additional benefits. As the market for aluminium alloys in automotive segment expands with inclusion of newer applications, Vedanta Aluminium will look for opportunities to leverage its technological expertise and R&D capabilities to develop products customised to the needs of the market. Vedanta Aluminium is also open to collaborating with the downstream industry, to unlock the entire potential of aluminium used in the auto sector and cater to the rapidly evolving aluminium requirements of the Indian automotive industry.

In the Indian automotive market, one of the biggest challenges faced today is the increasing imports of auto components from China and other countries. The size of the auto components imports was USD 17.6 billion in FY19. Asia, the largest source of imports for Indian auto-components, had a share of 61 percent followed by Europe at 29 percent; North America at eight percent; Latin America and Africa at one percent each in FY19. China, with 27 percent, enjoyed the status of the largest exporter in the Indian automotive market.

“The potential of the aluminium industry should be acknowledged and recognised as a core sector with a National Aluminium Policy that will encourage, protect and boost the domestic aluminium industry. The domestic capability needs to be harnessed for critical sectors of national importance like defence, aerospace, aviation, transportation, infrastructure, electrification, housing, etc. We must make the vision of ‘Make in India’ a ground reality in these sectors, leveraging the potential of the entire aluminium value chain, from mining to end usage. Besides enhancing domestic capacity and reducing import dependency and subsequently trade deficit, it will also generate huge employment opportunities in our country which has a deep talent pool that needs to be capitalised for the realisation of our vision of a USD5 trillion economy. We are on the right path, but there is still a long way to go,” said Kapur.

The global economy is swiftly moving towards a cleaner, greener and more sustainable lifestyle. For more than a decade now, concerns about fuel efficiency have encouraged OEMs to replace steel with aluminium in vehicle bodies, doors, trunks, hoods, bumpers, crash boxes, brakes and wheels. With the advent of electric vehicles (EV), OEMs worldwide are focusing on exploring and applying new uses of aluminium. The need for lightweight battery casings and heat exchangers in electric vehicles, combined with autonomous vehicles’ demands for high visibility and structural integrity, is expected to exponentially increase the use of aluminium in cars, trucks and buses from now on. “Using aluminium in EVs has several advantages, foremost amongst which is the distance travelled per charge. Lighter the vehicle, the longer its range. Coming to better battery life, thanks to the metal’s thermal and anticorrosion properties, aluminium is ideal for battery frames. Demand for aluminium will also rise on account of infrastructure for serving EVs since the metal is commonly used as a housing material for EVs charging stations as well. While India is waking up to this future of automobiles, partnerships between different automotive industry bodies/institutions and auto companies for sharing knowledge and expertise will help fast-track development of electric vehicles in the country,” said Kapur. MT

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Automotive Components Industry in India Focuses On Value Addition And Greater Agility

Automotive Components Industry in India Focuses On Value Addition And Greater Agility

In line with the government's push to make India a key automotive manufacturing hub, the automotive components industry in India is confident that it will export more in 2024. 

Focusing on providing more and more opportunities to Indian auto components manufacturers in terms of exports, the Automotive Components Manufacturers’ Association (ACMA) has been helping them to participate in major auto shows the world over. It is also conducting B2B trade fairs such as iAutoConnect which took place in November 2023 in New Delhi, to ensure good international exposure.  

Clocking a 12.6 percent Y-o-Y growth in the first two quarters (H1) of FY2024, the Indian auto components industry, informed an ACMA source, is riding on a robust domestic demand as well as concentrating on exports to ensure stronger and sustainable growth. 

Reporting sales worth USD 36.1 billion in H1 FY2024 as against sales worth USD 33.9 billion during the same period last financial year, the source mentioned that auto component manufacturers are paying attention to significant value addition by adopting new technologies and bettering their agility to respond to the market requirements in the international as well as the home markets. 

Speaking at a press event in Delhi recently, ACMA President Shradha Suri Marwah averred that the auto component industry is mulling over investing around USD 7 billion over the next five years on capacity expansion and technology upgradation mainly because of the robust demand within the indigenous automobile industry, 

"The components industry continues to make investments for purposes of higher value-addition, technology upgradation, and localisation to stay relevant to both domestic and international customers. The industry is aiming to invest USD 6.5-7 billion in capex over the next five years as compared to USD 3.5-4 billion spent in the last five years. With good performance in sales across segments of the vehicle industry in the festive season, I am optimistic that the current fiscal year will witness another good performance from the auto components sector," Marwah noted.

Speaking on the growth, she iterated, “As vehicles sales started reaching pre-pandemic levels and supply-chain issues witnessed during the pandemic such as availability of semi-conductors, high input raw-material costs and non-availability of containers were mitigated, the auto components sector witnessed a steady growth in both domestic and the international markets in the first-half of FY2023-24.”

The findings of the apex body indicated that the auto component sales to OEMs in the domestic market stood at USD 30.8 billion registering a growth by 13.9 percent compared to the first half of the previous year. Consumption of increased value-added components and the shift in market preference towards larger and more powerful vehicles continued to contribute to the increased turnover of the auto-components sector.

Moreover, exports of auto components grew by 2.7 percent to USD 10.4 billion in H1 FY2024 from USD 10.1 billion in H1 FY2023. North America and Europe accounted for 33 percent of exports witnessing an increase of 2 and 12 percent respectively, while Asia accounted for 24 percent, witnessed a decline of 4 percent.

The imports grew by 3.6 percent from USD 10.2 billion in H1 FY202-23 to USD 10.6 billion in H1 FY2023-24. Asia accounted for 63 percent of imports followed by Europe and North America, with 27 percent and 9 percent respectively. Imports from Asia grew by 2 percent, from Europe by 8 percent and from North America by 2.5 percent.

The aftermarket also registered a modest growth in H1 FY2024 witnessing sales go up by 7.5 per cent to USD 5.5 billion from USD 5.4 billion in H1 FY2023.

Commenting on the performance of the auto component industry in India, ACMA Director General, Vinnie Mehta, said, “With vehicle sales and exports displaying steady performance, the auto component industry demonstrated a growth of 12.6 percent scaling a turnover of Rs. USD 36.1 billion in the first half of FY 2023-24. 

Auto Component supplies to all segments of the industry i.e., to OEMs, exports and also the aftermarket remained steadfast. Exports grew by 2.7 percent to USD 10.4 billion while imports grew by 3.6 percent to USD 10.6 billion. The aftermarket, estimated also witnessed a growth of 7.5 percent. Component sales to OEMs in the domestic market grew by 13.9 percent to Rs.2.54 lakh crore”.

Elaborating on the mood of the industry and outlook for the near to mid-term future, Shradha mentioned, “Going forward, considering the festive season has gone well with significant sales across most segments of the vehicle industry, I am optimistic that the current fiscal year will witness another good performance from the auto components sector. The components industry continues to make investments for purposes of higher value-addition, technology upgradation, and localisation to stay relevant to both domestic and international customers.”

 

*Image for representative purpose only.

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SAEINDIA International Mobility Conference 2022

SAEINDIA International Mobility Conference 2022

All set to conduct its International Mobility Conference in Bengaluru from October 12 to October 14, SAEINDIA (Society of Automotive Engineers India) is highlighting sustainable multi-modal mobility. Revealing the theme of the event as ‘Sustainable Multi-Modal Mobility Ecosystem’, the organisation is banking on industry leaders from diverse fields like EVs, automotive and aerospace as its members to add value. 

Venkat Raj, Deputy Director, SAEINDIA, expressed, “We are looking at 7 STGs – sustainability goals – that include affordable, safe and environmentally friendly mobility. In addition to waterways, metros, etc, more is being awaited in a sustainable way.” Celebrating 25 years in India, SAEINDIA has been increasingly getting interested in mobility engineering,” he added. 

Held in a post pandemic environment, the event, termed as SIIMC 2022 in short, is the 10th such in a row. In what is regarded as the organisation’s Indian chapter’s flagship event, the SIIMC 2022 will see over 700 mobility experts including industry thought leaders and professionals from research and development, manufacturing and services along with faculties, students and independent researchers come together and discuss trends and innovations shaping the future of mobility. 

Mahesh Babu, Patron – SIIMC 2022, and CEO, Switch Mobility India, said, “As the highest growth country in the next decade, India has to find sustainable ways to grow including in the area of mobility.” Stating that demand for mobility would have grown 50 percent by 2020, he averred, “People mobility is going to put tremendous pressure and the need therefore is to focus on public transport as a means of sustainable development. This is necessary despite the count of personal vehicles in India being much less than that in US or Europe. Consider this: India has the lowest per capita bus fleet in the world amid huge urbanisation. There is a need by people and experts to together achieve a sustainable multiple mobility platform.” 

Building on the good response received by the 9th edition, the event committee received 530 papers and ideations. Of these 150 would be selected and presented across 5 parallel sessions. There will be over 50 stalls and an exposition. The highlight of this edition will be TechHive, an event for start-ups. Expecting a footfall of 800 visitors, the event will cover topics like automotive, connected tech, SG, vehicle electronics and software, AI, electric and urban air mobility among others. 

Focusing on hyperloop, inland waterways and urban mass transport, the event, according to Dr Shankar Venugopal, Vice President – MRV, Mahindra & Mahindra, will have sustainability, democratisation, disruption and digitisation as the undercurrents. Stating that the quest for increased mobility has left an impact on the environment, Dr. Bala Bharadvaj, immediate past President of SAEINDIA, mentioned, “Our ability in terms of technology is much better. Look at unmanned vehicles, quad-copters, etc, to support mobility, monitor crops and take pictures. Such scenarios make urban air mobility promising but not without its own set of complications.” “Would such mediums help avoid traffic jams on the roads an create new ones in the air makes it exciting as emerging possibilities. No mobility works independently and that makes it important to ensure sustainable mediums through greener fuels like solar.” 
 

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EcoFlow DELTA Pro Gets TIME Honour

EcoFlow DELTA Pro Gets TIME Honour

EcoFlow, a portable power and renewable energy solutions company, has been recognised by the prestigious Time awards for its pioneering product EcoFlow DELTA Pro. The portable power station made it into the “Time100 Best Inventions of 2021” list in the sustainable category.  

EcoFlow DELTA Pro, launched in July 2021, is designed to provide long-lasting backup during load shedding and allows users to better monitor and control their daily electricity consumption, the company said in a release. The company claimed that DELTA Pro can fully charge from a household outlet in three hours. It’s also chargeable from solar panels or electric-vehicle charging stations.  

With a 3,600-watt-hour capacity, it can keep household essentials running for nearly 24 hours, and multiple units can be networked together to power a whole house for days. DELTA Pro’s X-Boost’s single unit can go up to 4500W while X-Stream has the fastest recharging power station. It gets fully charged in 1.8 hours and can monitor voltage, output among others remotely, the release said. 

Jenny Zhang, Global Marketing Director, EcoFlow, said, “We are honoured to make it to the TIME’s lists that are giving recognition to the 100 inventions, which are ‘making the world better, smarter, and even a bit more fun’. Such honours show us that we are on the right track. Our EcoFlow DELTA Pro has been one of the ground-breaking inventions of the year that paves the way for the world to embrace alternative, sustainable power sources.” 

The company claimed that EcoFlow products are the world's first eco-friendly portable power stations. (MT)  

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Freudenberg Group Achieves Record Sales Globally

Freudenberg Group Achieves Record Sales Globally

Freudenberg Group, a renowned global technology conglomerate celebrating its 175th anniversary this year, has announced unprecedented financial achievements for the fiscal year 2023. The conglomerate reported a historic surge in both revenues and operating profits, with sales reaching USD 12.8 billion, marking a 1.3 percent increase from the previous year's figures. Additionally, the operating profit soared to USD 1.19 billion, an impressive 15 percent rise compared to the preceding year, and breaking the USD 1 billion mark for the first time in the company's history.

The robust performance was underscored by Freudenberg's steadfast commitment to innovation, customer-centric strategies and adaptable problem-solving approaches across diverse industries. The conglomerate's success story reflects its unwavering dedication to delivering cutting-edge solutions and fostering strong relationships with its clientele on a global scale.

Freudenberg's Indian arm also experienced remarkable growth, reporting substantial sales of over INR 38 billion for the fiscal year 2023. Demonstrating its confidence in the Indian market, the group announced investments totalling close to INR 3.5 billion slated for the CY2024. These investments are earmarked for enhancing facilities in key regions such as Punjab, Karnataka and Tamil Nadu. 

Notably, Freudenberg inaugurated a new production facility in Morinda, India, catering to its Vibracoustic Business Group and Freudenberg-NOK India joint venture. Moreover, the company's exports from India amounted to nearly INR 8 billion, highlighting its significant contribution to the country's economy.

In line with its global sustainability initiatives, Freudenberg Group is spearheading the transition towards renewable energy sources, aiming to achieve carbon neutrality by 2045. Sustainability lies at the core of Freudenberg's operations, with a focus on optimising energy and material resource utilization. The conglomerate is committed to reducing its CO2 emissions to zero by 2045 through a multifaceted approach encompassing energy conservation, electrification and the generation of green electricity.

Freudenberg's proactive stance towards sustainability is evident in its ongoing endeavours to harness renewable energy including solar and wind power systems. The conglomerate has installed approximately 20 new photovoltaic systems worldwide with plans for an additional 60 systems at various stages of planning and execution. These initiatives underscore Freudenberg's unwavering commitment to environmental stewardship and its determination to mitigate carbon emissions on a global scale.

Commenting on the group’s annual results and its financial figures made public, Chief Executive Officer, Dr. Mohsen Sohi, said, “Numerous records were set during fiscal year 2023. We achieved the highest figures ever for sales and operating profit. When we look back over the past 10 years, it becomes clear how impressive these figures are. Within a single decade, we have roughly doubled our sales and operating profit with an average annual growth rate of 6 and 7.7 percent, respectively. Our investments in research and development have grown by 9.4 percent annually, even more strongly and almost tripling. I would like to thank all our employees worldwide. Their commitment enabled us to achieve these historic results.”

Speaking at the occasion Director of Freudenberg Regional Corporate Center for India, G. Sivasailam, said, “As Freudenberg commemorates 175 years of operations globally this year, it is indeed a proud moment for Freudenberg India to be part of the continued growth journey. Freudenberg Group has been committed to its growing operations in the country, across diverse domains and across the group companies. We are continuing to invest in the expansion of our facilities and 2024 promises to be another year of key milestones we will achieve in India.”

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