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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Digital payment infrastructure company ToneTag has launched an in-car fuel payment system at the Global Fintech Fest 2026.

The solution is developed for TATA.CARS under the name DrivePay and integrates National Payments Corporation of India's UPI Circle framework for Internet of Things devices to enable direct fuel payments at IndianOil retail outlets.

The DrivePay platform integrates payment capabilities into connected vehicle infotainment screens. Drivers can simply pay at fuel stations from the vehicle dashboard without using mobile applications, physical cards, or external payment terminals.

The service also incorporates IndianOil’s XTRAREWARDS loyalty scheme, automatically crediting reward points to customer accounts without requiring mobile number inputs during checkout. Following the initial demonstration at GFF 2026, deployment will begin across IndianOil outlets ahead of a wider rollout.

Vivek Kumar Singh, Co-Founder and Director – Labs, ToneTag, said, "Payments are rapidly moving beyond traditional interfaces such as cards and smartphones, and connected devices are emerging as the next frontier for commerce. With DrivePay, powered by ToneTag, we are bringing an IoT-based UPI Circle payment experience directly into the connected vehicle. This initiative with IndianOil, TATA.CARS and NPCI demonstrates how payment infrastructure can seamlessly extend into connected devices, enabling the vehicle itself to become a secure payment interface. We believe this is an important step towards a future where mobility, payments and commerce are seamlessly connected."

The project combines IndianOil's retail distribution network, TATA.CARS' vehicle hardware, ToneTag's payment processing software and NPCI's UPI transaction network. ToneTag plans to extend its connected vehicle payment systems to additional automotive original equipment manufacturers and mobility providers.

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Hyundai Motor India, one of the leading passenger vehicle manufacturers, has introduced the Hyundai Bluelink Remote Immobiliser security feature for the Hyundai Venue and Venue N Line models.

The feature is available on the connected-car-Navigation-Cockpit equipped HX10 variant of the Venue and the N10 variant of the Venue N Line.

The security system allows vehicle owners to immobilise a parked car via the Hyundai Bluelink mobile application, preventing engine restart in scenarios involving key cloning or unauthorised access.

In cases of suspected theft, users can trigger the immobiliser remotely, locking the engine start capability once the ignition is turned off. The system operates alongside network-dependent live location tracking to assist vehicle recovery. For safety reasons, the software does not cut power or shut down an active engine while the vehicle is in motion.

The feature is being deployed via a Controller Over-the-Air update leveraging Hyundai's Software-Defined Vehicle (SDV) architecture. Eligible Venue and Venue N Line models sold since November 2025 will receive the update automatically without requiring physical service centre visits. The ccNC system allows over-the-air updates across up to 19 individual vehicle controllers.

Furthermore, From September 2026, the remote immobiliser will be standard equipment on HX10 and N10 variants, with plans for phased implementation across other Bluelink-enabled models.

Tarun Garg, MD and CEO, Hyundai Motor India, said, “With Hyundai Bluelink now powering over eight lakh connected vehicles in India, we continue to strengthen our connected mobility ecosystem by delivering meaningful innovations that address evolving customer needs. Hyundai Bluelink Remote Immobiliser offers customers greater control and peace of mind by enabling them to remotely secure their parked Hyundai VENUE or VENUE N Line and respond quickly in the event of suspected theft, while incorporating safeguards that prioritise customer safety. Importantly, this feature also demonstrates the future-ready potential of Hyundai’s Software-Defined-Vehicle architecture. Through a seamless Controller Over-the-Air update, we are introducing an important new capability to eligible model variants without requiring customers to visit a workshop.”

At present, Hyundai Motor India offers the Bluelink connected car system across 11 of its 15 vehicle lines in the country, providing functions including emergency crash notifications, vehicle diagnostics, remote telemetry and voice command controls.

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Bosch Software and Digital Solutions (Bosch SDS) has entered into a collaboration with Dassault Systèmes in India, aimed at helping manufacturing enterprises accelerate digital transformation across product engineering, manufacturing operations and industrial value chains.

The partnership combines Dassault Systèmes’ capabilities in Virtual Twin Experiences, Product Lifecycle Management, Digital Manufacturing and Manufacturing Operations Management with Bosch SDS’ expertise in contextualised data products, manufacturing transformation, energy optimisation, IT/OT integration and machine-level intelligence. It also draws on both companies’ global industrial AI expertise. Early momentum has been demonstrated through an engagement with a leading Indian electric vehicle manufacturer, where Dassault Systèmes’ DELMIA Apriso MES platform and Bosch SDS’ manufacturing transformation capabilities are being deployed to enable intelligent, real-time connected operations, yielding improvements in production efficiency, quality and digital traceability.

Under the collaboration, the two organisations will jointly work across several identified areas. These include AI-enabled manufacturing transformation and Agentic AI orchestration through the Bosch Cognitive Factory platform; Digital Thread and traceability across engineering, manufacturing and lifecycle operations; contextualised data products and enterprise intelligence; energy management, sustainability transformation and an Energy Management Platform; smart factory, connected operations and IT/OT convergence with machine-level intelligence and Digital Product Passport and regulatory compliance readiness. Joint market engagement will extend into heavy engineering and process sectors, leveraging the complementary domain strength and technology depth of both organisations.

Bosch SDS will serve as a Consulting and System Integration partner to Dassault Systèmes across the identified transformation areas, spanning engineering, manufacturing and enterprise operations. Both organisations will jointly innovate and develop solutions to support customers in deploying end-to-end AI, Digital Thread and AI-enabled Digital Product Passports across product and manufacturing value chains.

Dattatreya Gaur, MD & CEO, Bosch Software and Digital Solutions, said, “Manufacturing enterprises today are looking beyond isolated digitisation initiatives towards connected, intelligent and autonomous operations. Our collaboration with Dassault Systèmes brings together two highly complementary strengths in Industrial AI: Bosch SDS’s deep expertise as a technology partner and practitioner across manufacturing, operational technology integration along with the Bosch Cognitive Factory platform, and Dassault Systèmes’ leadership in Virtual Twin Experience and Digital Thread capabilities. Together, we are uniquely positioned to help manufacturers accelerate AI-led transformation across the entire product and manufacturing value chain with greater speed, intelligence and scale.”

Ramesh Ramaswamy, Global Sales Head, Bosch Software and Digital Solutions, said, “The future of manufacturing will be defined by how seamlessly enterprises connect engineering, operations, data and AI across the value chain. Through this collaboration, Bosch SDS and Dassault Systèmes are bringing together complementary strengths to help manufacturers move from fragmented transformation efforts to truly connected, software-defined and intelligent operations. This creates a far stronger foundation for manufacturers to scale innovation, resilience and operational agility in the AI era.”

Deepak NG, Managing Director, India, Dassault Systèmes, said, "Our collaboration with Bosch SDS marks a major milestone for the manufacturing industry. By connecting our virtual twin technology with their industrial expertise, we are helping factories adopt AI much faster. This will create highly connected and sustainable operations. Together, we look forward to helping companies innovate and grow in the digital era.”

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Tata Motors and PETRONAS Lubricants India have inked a Memorandum of Understanding (MoU) to establish a collection and recycling program for used automotive lubricants.

The two companies will launch the pilot project simultaneously across Maharashtra and Tamil Nadu to evaluate a scalable model for lubricant waste management.

The initiative creates a traceable system for collecting, storing and processing used lubricants through registered recycling channels, with the goal of converting collected waste into re-refined base oil.

Tata Motors will utilise its authorised service centre network to facilitate collection, while PETRONAS Lubricants India will oversee the logistics and transfer of used oil to certified re-refiners. The collaboration aligns with India's Extended Producer Responsibility regulations governing hazardous waste disposal.

Binu Chandy, India Managing Director at PETRONAS Lubricants India, said, "Achieving true circularity in used oil begins when re-refined base oil is reintegrated into finished lubricants. Our collaboration with Tata Motors marks an important step toward building a scalable model for used oil circularity and reflects the strength of our channel network as we work to significantly reduce our carbon footprint across operations."

Vikram Agrawal, Head of Spares and Non-Vehicle Business, Tata Motors, said, "At Tata Motors, practices and partnerships promoting sustainability are integral to advancing circular economy principles and creating meaningful environmental impact across the automotive value chain. Through our collaboration with PETRONAS Lubricants India, we are taking a significant step towards establishing a structured framework for the collection, recovery, and recycling of used automotive lubricants. This pilot initiative aligns closely with our commitment to responsible resource stewardship and supports India's broader sustainability ambitions. By bringing together the complementary strengths and expertise of our two organisations, we aim to assess the viability of a scalable used-oil recycling model that can drive long-term value and contribute to industry-wide progress."

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