Abilities India Sets New Standard in Lightweight Piston Manufacturing

Indian manufacturing company Abilities India Pistons & Rings Ltd. has announced the grant of its second patent for its innovative High-Pressure Die Casting (HPDC) process. This breakthrough is set to revolutionize lightweight piston manufacturing, reducing the weight of 2W/3W pistons by 10-15%. With the current annual output of 20 million 2W/3W vehicles, this advancement will result in a substantial annual aluminum saving of 307.5 tons. By 2030, the annual saving is projected to increase to 461.25 tons. This reduction corresponds to carbon emission savings of 920 tons per annum, with a projected increase to 1380 tons per annum by 2030.

Driving Self-Reliance in Indian OEMs: Abilities India’s immediate priorities include leveraging these patented technologies both domestically and internationally. The company aims to support the self-reliance goals of leading Indian Original Equipment Manufacturers (OEMs) by developing critical components. This underscores the company’s commitment to pushing the boundaries of automotive manufacturing and supporting sustainable practices.

Impressive Financial Performance and Growth Projection: The company’s financial performance aligns with its commitment to technological advancements. In FY24, Abilities India achieved a noteworthy revenue of INR 128 Cr. Looking ahead, the company is poised for substantial growth with a projected top line of approximately INR 225 crore in FY 2026. Additionally, it aims to increase its EBIDTA from 14% in FY 2024 to approximately 16% in FY 2026. These growth projections are driven by AR’s belief in the transformative power of innovative technological solutions within the automotive industry. To support its growth trajectory and fuel further innovation, Abilities India plans to double the size of its Research and Development (R&D) team. The company also aims to increase the fund allocation for R&D from the current 2% to 3% of revenue.

Expansion Plans and Increased Investments: Currently, Abilities India’s manufacturing facility spans 5 acres in a single location, with a built-up area of 14,153 square meters. The company intends to expand its manufacturing facility by an additional 3000 square meters in FY25/26, investing approximately INR 20 crores. This expansion follows a recent investment of INR 17 crores in FY24. The increased investment will cater to the growing demand for Abilities India’s groundbreaking technological solutions.

The High-Pressure Die Casting Process: Innovation in Piston Manufacturing: Traditionally, pistons for gasoline and diesel engines are produced using the Gravity Die Casting (GDC) process, known for mass production optimization. However, this process is limited by thicker wall thicknesses and higher machining allowances. Abilities India’s High-Pressure Die Casting (HPDC) process revolutionizes lightweight piston manufacturing. By subjecting molten metal to high pressure within a mold, the HPDC process achieves intricate contours and desired geometry. This innovation significantly reduces the need for extensive machining, resulting in pistons with minimal machining requirements. The HPDC process caters to the evolving needs of the automotive industry, including tightening emission standards and the demand for lightweight, high-performance engine components for 2-stroke and 4-stroke engines. This game-changing technology enhances fuel efficiency and engine performance, while also reducing material usage and carbon emissions. Abilities India’s commitment to research and development ensures continuous innovation, exploring avenues to enhance coating properties and broaden applications in order to meet the growing demand for advanced automotive components.

Commentary from Company Officials: Sunil Arora, Chairman and Managing Director of Abilities India Pistons & Rings Ltd., expressed the company’s dedication to pioneering research and technological advancements in the auto components industry. Arora emphasized that the development of the second patent highlights Abilities India’s unwavering commitment to innovation and sustainability in automotive manufacturing. By improving engine performance and actively reducing emissions, the company aims to shape the future of automotive technology and set the industry standards for sustainable and efficient solutions. Joint Managing Director and CEO Tushar Arora emphasized the transformative potential of the newly patented HPDC process in the automotive industry. The reduction in piston weight leads to enhanced fuel efficiency and engine performance, as well as decreased material usage and carbon emissions. The company is excited about the possibilities that this innovative technology brings. With its continuous dedication to research and development, Abilities India remains committed to meeting the growing demand for advanced automotive components, enhancing coating properties, and exploring new applications.

Aayush Kukreja Apart from being a literature student and a theatre practitioner, Aayush is a daydreamer! He loves poetry and just as a poet should be, he’s witty, opinionated and completely clueless about life. Reach out to him anytime for some good old sher-o-shayari. Here, he writes about the quirkiest and the most interesting of things. To the rhythm of life and words, cheers!
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