Will Nano plant take off ?

Industry appeal for immediate solution to Singur crisis


Visibly upset over the mounting tension and the growing threat to property at Tata Motors’ Nano small car project at Singur in West Bengal in the wake of the ongoing agitation against the unit by Trinamool Congress, under its leader Ms. Mamata Banerjee, and its allies, the Tata Group Chairman, Mr. Ratan Tata, recently announced his intention of moving out of Singur. He made it very clear then that the project cost of Rs. 1,500 crores won’t deter him from proceeding with his plan if the agitation persisted. The crux of the problem is Ms. Banerjee’s demand that the 400 acres out of 997 acres of land taken possession of for the car project, allegedly acquired by the management without the consent of the peasant-owners and by using force, be returned to them. This has been countered both by Tata Motors and the State Government stating that the land deal done was most transparent and that adequate compensation had been paid to the owners. Further the issue is being raked up by certain vested interests to gain political mileage.

Firm on continuing the agitation till the return of the land to those from whom it has been snatched away, Ms. Banerjee launched an indefinite stir at the project site on August 24. This has its serious consequences. With the blockade of the expressway passing through the area, truck operations along the route have come to a standstill, leading to widespread shortage of foodstuff and other essentials there. At the same time, the agitators continue indulging in violence. In the circumstances, the Tata Management did what could have been avoided had the agitators restrained themselves. Work at the project site was suspended on August 29 when the protestors prevented the employees and other contract workers from leaving the factory the previous day.

The situation is definitely getting out of control at the project site. The earlier hopes expressed by industry associations and the State Government that the Singur project will sail through somehow with the expected fizzling out of the agitation or a negotiated settlement worked out by the parties to the dispute are fading. Instead serious concern has been expressed by industry leaders all over the country, irrespective of their areas of specialisation, over the Singur developments. They have joined hands to back Tata Motors in its endeavour to roll out the first vehicle from the Singur plant as scheduled in October, and have appealed to the parties concerned for working out an immediate solution to the Singur crisis.

Industry appeal

The Society of Indian Automobile Manufacturers (SIAM) would like to see an early resolution in Singur. It is disappointed with the developments there. The investments being made would result in a product that is a global first, and hence global attention is on the developments there.

SIAM believes that this was a landmark decision by the company that could and will change the lives of people in the area and also revive industrialization in West Bengal and the eastern region.

The progress of the investment is such that the factories have been built, and therefore it is important to find a solution that does not adversely affect the investments made and, most importantly, the overall competitiveness and viability of the project.

SIAM would like to appeal to all concerned that a process must be initiated to arrive at a solution that would take forward the project so that production targets are not missed. Such a solution would ensure that the investments of over Rs. 70,000 crores committed by the automotive industry to be made in the country over the next few years would happen.

Mr. R. Seshasayee, Past President of SIAM, and Managing Director, Ashok Leyland, observes: “The Nano is certainly a flagship project and withdrawal of this project would adversely affect not only the image of the State but also the country. It is imperative that all political parties come together now and arrive at a solution. It is critical to distance this discussion from the factory side so that normalcy can be restored immediately.”

According to Mr. Sunil Kant Munjal, Chairman, Hero Corporate Service, it is in the interest of both West Bengal and India that the Tata Nano project is not moved at this stage. Withdrawal of the project will severely affect West Bengal’s image, and it certainly won’t do India’s image any good. Political parties must rise above partisan lines, ensure continuity and growth in economic activity and also help in creating a peaceful environment.

Of course, the investing entity has a responsibility to take care of the interests of all stakeholders, including people who are displaced or re-employed, etc. “Indeed, given their level of social commitment, I have no doubt that the Tatas are fully aware of their responsibilities in Singur as they have demonstrated in many of their companies. All possible efforts must be made to ensure that the project is implemented peacefully and on schedule. This would be in the interest of the community and for nation-building”.

Mr. Brijmohan Lall, Chairman, Hero Honda Motors Ltd., joins the industry leaders, and says: “The leadership demonstrated by Mr. Ratan Tata on the Singur issue is commendable. His determination to go ahead with the Nano project this far reflects his deep commitment to the State of West Bengal and, more importantly, demonstrates his resolve to keep a promise. It would be really unfortunate if circumstances continue in this manner and the Tatas are forced to pull out. All political parties need to come together to ensure that this project happens.”

Mr. Abhay Firodia, Chairman and Managing Director, Force Motors, said: “The automobile industry is the engine of growth for any economy. All over the world, countries have developed on the back of automobile industry. Nano is a huge opportunity for West Bengal due to its deep forward and backward linkages. People should understand the importance of the project and resolve the dispute at the earliest.”


Reacting to the situation Mr. Venu Srinivasan, Chairman and Managing Director, TVS Motor Company, commented: “Considering the national importance of this project, it would be unfortunate if political considerations come in the way of India’s progress”.

Over 4,600 exhibitors expected at Automechanika in September

Messe Frankfurt expects over 4,600 exhibitors and around 160,000 trade visitors to attend the 20th Automechanika being held from September 16 to 21. Since making its debut in 1971, Automechanika has developed into one of the most important meeting places for decision makers from the automobile sector. The main theme of this year’s fair is: “Global warming and its impact on the automotive aftermarket”. What is the significance of the latest innovations in the fields of emissions protection and CO2 reduction for the parts market? What recommendations does the sector have for workshops, filling stations and their service offers? Answers to these sessions will be available at the fair.

Visitors will find, for example, a ‘Green Directory’ that draws attention to products distinguished by energy and material efficiency or advances in emissions protection. At the Automechanika Academy, too, experts will discuss the reaction of the trade to demands for CO2 reductions.
Held every two years, Automechanika offers trade visitors a unique range of products in the automobile parts, car washes, workshop and filling-station equipment, accessories and tuning sectors. The fair is unparalleled in terms of size and internationality with around 40 per cent of trade visitors and 80 per cent of exhibitors at the last event coming from outside Germany.

Covering nearly 300,000 square metres of exhibition space (gross), Automechanika occupies almost the whole of the Frankfurt Fair and Exhibition Centre, including, for the first time this year, the new Southwest Outdoor Area where exhibitors from the car-wash business like WashTec Cleaning Technology GmbH, Otto Christ AG, Holz Autowaschtechnik GmbH, Alfred Kärcher Vertriebs-GmbH and Istobal S.A., will make their presentations.

It was a good 10 years ago that Messe Frankfurt launched the first Automechanika fair outside Germany. Today, Automechanika has developed into a potent trademark or ‘brand’ with 12 events in 10 countries on three continents. Two new events were held last year alone: Automechanika Moscow from May 13 to 16, 2007, and Automechanika Canada from September 26 to 28, 2007, in Toronto.
A very special debut follows early this year: the first Automechanika in Southern Europe, Automechanika Roma from January 31 to February 3. Over 200 exhibitors from more than 14 countries have registered for the première, which is the first event to be held by Messe Frankfurt in Italy since founding its subsidiary there in 1999.

Detlef Braun, member of the Board of Management of Messe Frankfurt, said: “We will continue observing and analysing the world’s markets in the future so that international manufacturers and buyers have the chance to make contact with national companies and business partners. Our events outside Germany represent launching pads into emerging markets, especially for small to medium-size companies. Naturally, we will organise additional events for the automotive sector should the conditions for the industry prove to be favourable”.

Today, the name Automechanika is a seal of quality when it comes to trade fairs for automobile parts, workshop and filling-station equipment and for accessories and tuning parts. The broad range of products to be seen is unparalleled.

The basis of this success is the leading Automechanika fair in Frankfurt with its high degree of internationality on both the exhibitor and visitor sides and its international reputation. The Frankfurt event is a pointer for questions of strategy and puts the focus on the right subjects and the right time. And this has been rewarded by an increase in the number of visitors from outside Germany. Moreover, more people travel to Frankfurt from those countries where Messe Frankfurt holds subsidiary fairs than ever before.

Mahindra International is now Mahindra Navistar

Trucks to roll out by 2009-end
Mahindra International, the 51:49 joint venture between the Mahindra Group and International of the US, has been renamed as Mahindra Navistar Automotives Ltd. (MNAL), while Mahindra’s JV with International for manufacturing engines will be named Mahindra Navistar Engines Ltd.

MNAL is setting up its manufacturing facility in Chakan, near Pune, and will roll out its M&HCV trucks by the last quarter of 2009. The new JV will manufacture a range of trucks starting from 3.5 tonne to 49 tonne GVW, says Mr. Rakesh Kalra, CEO of MNAL.

The JV agreement was originally signed in November 2005, and the plan was to roll out trucks by the end of 2007. But there was considerable delay in acquiring the land from the Government. “From the time the land was handed over, we have made very good progress on the project, and we are confident that we will be able to roll out our trucks by end of 2009”, says Mr. Kalra.

Mr. Rakesh Kalra joined MNAL in 2007 and had the major responsibility of establishing a brand name in the commercial vehicle segment before launching its M&HCV range. In the last 18 months the emphasis was clearly on the company’s current range of LCVs, both in the passenger and cargo segments, and ensure that it has the distribution channel in place and also serve the existing customers.

The company efforts have paid off. In the recent customer satisfaction survey done by TNS for the LCV segment, MNAL has been the voted the second best, just a few points below Tata Motors. This is a great achievement considering the fact that this is the first time that Mahindra vehicles have been included in the survey. Mr. Kalra is extremely happy with the way things are progressing.

MNAL is currently operating through the dealerships of Mahindra Automotive Sector. The company has been able to increase proliferation of spare parts across all major markets, which becomes very important from the after-sales and service point of view. The objective is to take care of the existing customers and ensure that by the time the M&HCV range gets launched in the market, there is better acceptance of MNAL’s range of commercial vehicles. The company is also looking at establishing an independent sales and service network.
Currently MNAL is striving to consolidate its position in the LCV segment, both passenger and cargo. It registered a growth of 20 per cent and in 2007-08 by selling 11,000 LCVs, which is an equal mix of both passenger and cargo vehicles. MNAL has strengthened its position in the school bus segment. Today the product range in passenger segment includes 16, 25, 32 and 41-seater buses.

Another important area of focus, Mr. Kalra says, is the CNG segment. With many cities and States taking to CNG as an alternate fuel, the company clearly sees an opportunity for CNG vehicle. It has already launched the CNG passenger version and will very soon launch the CNG cargo version as well.

In terms of markets, MNAL which has been traditionally strong in Tamil Nadu and Kerala has now strengthened its presence in the other southern States of Andhra Pradesh and Karnataka. The company has also enlarged its presence in the North, particularly in markets like UP.

Updating the new plant coming up in Chakan, Mr. Kalra says: “We are moving very swiftly forward according to our plans. The plant is an integrated facility which is coming up in Chakan which also includes the engine plant. We are confident of achieving close to 100% indigenisation on all our vehicles”.

A team of over 200 engineers is working on the new products that would be launched in India. Another team of 500 engineers from Mahindra Engineering Services has been supporting the Indian project as well as for Navistar’s global requirement.

Hyva Group takes over Tecnomet

The Hyva Group, the global provider of efficient transport solutions for commercial vehicle and environmental services industries, has announced acquisition of Tecnomet, a manufacturer of double acting cylinders. Tecnomet which has a manufacturing site in the northern part of Italy is one of the three main suppliers to Hyva’s wholly-owned subsidiaries, AmcoVeba and F.lli Ferrari.

Double acting cylinders are used in hook lifts, skip loaders, moving floors, cranes, compactors and refuse collection vehicles, all of which are produced by Hyva manufacturing facilities around the world.

The acquisition of Tecnomet will thus be a good supplement to Hyva’s operations, providing the opportunity to transfer the double acting technology to its manufacturing sites worldwide.

Commenting on the acquisition, Louwrens Dijkstra, Hyva CEO, said: “The Tecnomet acquisition is a major milestone in our vertical integration strategy. It will enable Hyva to source a larger part of its internal requirement in-house as well as becoming a supplier of double acting cylinders in general. It will also provide us with the opportunity to transfer the double acting technology to emerging countries where we can capitalize upon the same type of technology and where we sell and manufacture for the respective domestic markets.”

The Hyva Group is committed to the development, production, marketing and distribution of components used in hydraulic loading and unloading systems on trucks and trailers. Its products are used worldwide across a range of sectors, including transport, construction, mining, materials handling and environmental services providers.

Hyva produces the strongest front end hydraulic telescopic cylinder in the world, double acting cylinders, fixed mounted and rolling truck cranes, container handling systems such as hook loaders and skip loaders, mobile and static compactors and other waste collecting units.

Hyva’s portfolio comprises hydraulics (cylinders and tipping gear), container handling systems (hook and skip loaders), floors (horizontal unloading/loading floors) and cranes (fixed and rolling). These products are designed and marketed under several well respected brands: Hyva, Kennis, F.lli Ferrari and AmcoVeba.

Hyva is also a distributor of high value components. Founded in 1979, the company is headquartered in Alphen aan den Rijn in the Netherlands and has significant manufacturing facilities in Brazil, China, Germany, India and Italy. Operating in more than 130 countries the company has more than 1,600 employees around the world, encompassing 35 subsidiaries and 11 production facilities.

For details, visit www.hyva.com

Federal-Mogul’s plan for new production facility in Chennai

Federal-Mogul Corporation is planning to build a new facility in Chennai, for the manufacture of friction components for OE and aftermarket segments. The operation is scheduled to begin production of light vehicle brake and friction components and commercial vehicle and railway friction products by September 2009.

Federal-Mogul currently manufactures products at six centres in India, including pistons, rings, liners, bearings, ignition and sintered products for both OE and aftermarket customers. The locations are Bangalore, Bhiwadi (two units), Khandsa, Parwanoo and Patiala. Its Ferodo friction products are manufactured in India since 1995, although the new friction facility will be its first in the Chennai region.

Federal-Mogul’s wholly-owned subsidiary in India recently signed a memorandum of understanding with New Chennai Township Pvt. Ltd., a subsidiary of MARG Ltd., to buy 10 acres of land on which it will build the 6,000-sq. metre facility. The plant, to be built in three phases, will eventually cover 15,000 sq. metres and create approximately 500 jobs.
“This new greenfield facility is another example of Federal-Mogul’s commitment to expand its manufacturing footprint in India. Products manufactured at the new facility will be for both local vehicle manufacturers and for export”, said Federal-Mogul President and Chief Executive Officer José Maria Alapont.

“We are the leader in supplying Ferodo brand vehicle brake friction components, and we continue to have excellent opportunities for growth. We are happy to expand our presence in India. The new facility in Chennai is an investment to enlarge and diversify our presence in India in support of market growth, and further demonstrates our commitment to sustainable global profitable growth strategy,” Alapont added.

Federal-Mogul which supplies systems protection products is one of the world’s largest suppliers of friction materials. Both the systems protection and friction products are used in the automotive, heavy-duty, motorcycle, railway and consumer products markets. The primary products include brake disc pads, brake shoes, brake linings and blocks.

The company offers a portfolio of world-class brand names, including Abex, Beral, Ferodo, ThermoQuiet and Wagner. It supplies friction and systems protection products to all major customers in the light vehicle, commercial vehicle and railway sectors and is also a leading company in the aftermarket.

Federal-Mogul Corporation is a leading global supplier of powertrain and safety technologies, serving the world’s foremost original equipment manufacturers of automotive, light commercial, heavy-duty, industrial, agricultural, marine, rail, off-road and industrial vehicles, as well as the worldwide aftermarket. The company’s leading technology and innovation, lean manufacturing expertise, as well as marketing and distribution deliver world-class products, brands and services with quality excellence at a competitive cost.

Federal-Mogul is focused on its sustainable global profitable growth strategy, creating value and satisfaction for its customers, shareholders and employees. Federal-Mogul was founded in Detroit in 1899. The company is headquartered in Southfield, Michigan, and employs 50,000 people in 35 countries. For details, visit www.federalmogul.com

Harita Seating’s JV with Fehrer

Harita Seating Systems Ltd., the Chennai-based automotive seating solutions supplier, has signed a letter of intent for a joint venture in Chennai with F.S. Fehrer Automotive GmbH, the international specialist for vehicle interior components based in Kitzingen, Germany.

The joint venture, expected to be operational in three months, will be called Harita-Fehrer Ltd., with Harita Seating Systems Ltd. holding 51 per cent and Fehrer 49 per cent.

The production program of the joint venture includes polyurethane moulded foam pads for seats and plastic components for the Indian automotive market as well as motorbike seats. The production facilities are in Hosur and Pune.

For the near future, the partner companies plan to expand the capacities for the seat bolster production and extend the product portfolio by armrests and headrests for the Indian automotive market.

“Harita-Fehrer combines leading and reliable Fehrer expertise in the complete value-added chain with the distinct market access of Harita. Thus the joint company guarantees custom-made products for India’s automotive industry which meets international quality requirements”, says Dr. Bernd Welzel, CEO of the Fehrer Group.

Fehrer Automotive GmbH, founded in 1875, has customer-oriented service centers and production locations worldwide. The development and production range includes seat bolsters for vehicles, seat modules (armrests, side parts, headrests and back panels), roof trim parts and seating structure parts for convertibles / coupe as well as trim parts for sunshades.

With over 3,000 employees at 20 locations in Germany, Sweden, the Czech Republic, Russia, the US, Spain, Brazil and South Africa, Fehrer achieved a turnover of EUR 420 million in the past year.

Harita Seating Systems, a manufacturer of complete vehicle seats for commercial vehicles and buses, is promoted by members of the TVS family. The TVS Group has more than 30 companies, over 40,000 employees, an annual turnover of $3.1 billion and is one of the largest component groups in the Indian automotive industry.


Harita Seating has a leading and dominant position in the tractor and commercial vehicle driver seats as well as the premium bus passenger seats in the Indian market.

Evolution of Indian tipper segment

By Ajay Gupta, CEO and Director and U.K. Goel, Director, CEBBCO
The Indian tipper manufacturing industry has undergone a sea-change in the last three decades. During the 1970s and 1980s, tipper bodies were mainly manufactured by the unorganized sector on tipper chassis supplied by Tata Motors Ltd. (then TELCO) and by Ashok Leyland Ltd. There was basically one model of chassis from each manufacturer with two different wheel base configurations.

Telco supplied semi-forward control 1210SK with 3600 mm and 3200 mm wheel base with three body types, namely, Scoop Type 4.5 cum, Box Type 6 cum & Coal Carrier 8 cum, while Ashok Leyland supplied Cheetah full forward tipper chassis for 6 cum body. Vehicles with tipping cylinder fitted under the body are known as UB tippers.

Chassis manufacturers were selling tipper chassis with PTO and hydraulic pump fitted on gear box, and the body was made outside. Telco supplied its own brand of PTO / pump / hydraulic kit and Ashok Leyland used Usha telehoish kits. During the period, small capacity tippers were used by large contractors for loading earth and coal employing 2.5 cum shovels and loaders. The life of the tippers is shorter due to the loading impact.

There were only a couple of body builders in the organized sector then – Commercial Engineers and Body Builders Company (CEBBCO) and Kailash Auto Builders set up in years 1980/1984 and Utkal Auto at JSR catering to this segment. Quality of cabin & body building was very poor as both were made by roadside fabricators. Only Tata Motors Ltd. Supplied Cab Kits to their Body Builders. But overall Quality was not very good and customer had little choice.

In the 1990s, Wipro of Bangalore started supplying hydraulic kits suitable for Tata Motors and Ashok Leyland chassis. A few companies like Allwyn Nissan, Swaraj Mazda, DCM Toyota and Eicher Motors entered the tipper market quite late.

In the 1990s, the first foreign company from Holland, Hyva (India) Ltd., introduced the Hyva brand hydraulic kits with telescopic cylinders for the front end tipping configuration, mainly for newly launched Tata tipper multi-axle chassis model 2516 and Ashok Leyland 2516 chassis suitable for 14/16/18 cum tipper bodies. Hyva set a new market trend in India as well as a benchmark for quality. All the chassis brands launched since 2000, like Volvo, MAN, Mercedes, AMW, opted for Hyva hydraulic kits.

Hyva also started fabrication activity with multi-location plants. Front end tippers (FETs) are now the preferred choice of customers.

In 2006, Tata Motors also introduced full forward control tippers upto 10 cum range in on models LPK 1613 / LPK 909 / LPK 407 with options like heavy duty / light duty bodies.

Current status

Since 1996, tipper body building in India remains confined to the organized sector, with the entry of new players like JBM, Stokato, Vectra Azad, ACCL, etc. The opening up of the infrastructure sector has generated huge demand for tippers, and the total market has grown by almost 33 per cent over the years. Prospects for the sector are brighter due largely to expanded construction activity related to high-rised buildings, roads, airports, power plants, etc.

Presently total size of tipper market is
3 – 4 Cum 2000 Nos. p.a.
5 – 6 Cum 5000 Nos. p.a.
8 – 10 Cum 15000 Nos. p.a.
Above 14 Cum 30000 Nos. p.a.
Total: 52000 Nos. p.a.

Tipper supplies during last five years are given below:
2003 – 04 19500 Nos.
2004 – 05 28300 Nos.
2005 – 06 31000 Nos.
2006 – 07 35000 Nos.
2007 – 08 52000 Nos.

Growth prospects

The outlook for hydraulic kit manufacturers and body fabricators is quite encouraging with the expected economic growth of eight per cent.

Estimated tipper requirement in next five years are given below:
2008 – 09 57000 Nos.
2009 – 10 65100 Nos.
2010 – 11 67800 Nos.
2011 – 12 72200 Nos.
2012 – 13 77000 Nos.

There is enormous scope for new players in the field, since the volumes provided by Wipro and Hyva are very limited.

CEBBCO and Kailash Vahan Udyog Ltd. (KVUL) are currently the largest manufacturers of tipper bodies in India with an annual capacity of 15,000 units, which is proposed to be raised to 25,000 units.

CEBBCO has its plants at Jabalpur in MP, while KVUL’s plants are located in Bangalore and Pune. CEBBCO is putting up a new plant at Pithampur to build body on Eicher, Volvo and MAN chassis, and KVUL is setting up its plant in Uttaranchal for body building on Ashok Leyland chassis. Both the companies are major suppliers to Tata Motors Ltd., Ashok Leyland Ltd. and Eicher Ltd. and opportunities exist to supply to Mahindra International and other new entrants.

Growing vehicle population and road accidents

By S.R. Venkatesan, Consultant
Safety on Indian roads is a most critical issue. With the growing vehicle population and expanding traffic on Indian roads, the issue, which has assumed serious proportions of late, needs to be addressed on a war footing. Almost 10-12 precious lives are being lost every hour on Indian roads leading to great social cost, besides mental agony and trauma for the close relatives of the victims.

With the ongoing globalisation, India is fast emerging an economic superpower, and despite the present challenges in terms of rise in inflation caused by shooting fuel prices, the long-term road map looks promising. Mobility is basic for growth on sustainable basis, and with expanding economic activity, there is greater need for stepping up goods and passenger transport facilities.

A commercial vehicle owner / operator is always keen on minimising operational costs and maximising revenues. Almost 75 per cent of goods and 85 per cent of passengers are being moved by road. This throws up the biggest challenge in terms of safety and security as well as CO2 emission, air pollution and fuel shortage.

India has joined WP-29, the world forum for vehicle regulations harmonisation. This will make it necessary for the country to adhere to global safety and emission standards. This will also lead to local manufacturers adopting global standards and introducting advanced technological features as well as help in seamless integration of international regulations.

There are an estimated 90 million vehicles in India, of which 5 millions are commercial vehicles. For a very long time, Indian roads were ruled mostly by 2-axle: 4x2 trucks being manufactured and supplied by the leading CV majors, Tata Motors and Ashok Leyland. In the 1970s, Ashok Leyland introduced a range of multi-axle rigid truck and tractor-trailer models, Beaver / Hippo / Taurus, which were quite popular on Indian roads when it came to higher gross weight operations and ODC movements in India.

Demand for multi-axle trucks and articulated vehicles has been on the increase in the last five years. However, higher gross weight vehicles, increased mobility and higher vehicle speed have resulted in a large number of road accidents and fatalities.

More than 12 lakh persons die every year in road accidents worldwide. In India, the number of fatalities has crossed an alarming level of 1,00,000 per year. A detailed analysis cites several reasons for the growing road accidents in India. With almost 70 per cent of vehicular population being two-wheelers, it creates a non-homogenous mix of vehicles affecting smooth traffic flow. The large number of rail level crossings and the use of old vehicles are a major hindrance, besides road user’s behaviour, poor safety awareness among pedestrians, cyclists and two-wheeler drivers who are most vulnerable to accidents on Indian roads. Overspeeding, wrong overtaking and drunken driving, besides excessive truck and bus driver fatigue, add to the woes.

The Government and all stakeholders like vehicle manufacturers and automobile associations and institutions have been constantly addressing the issue of road accidents and fatalities and working out remedial measures. One of the recent initiatives in this direction was the setting up of the National Safety Board. Driver training, better traffic management, good roads, a road map for vehicular technologies, safety awareness campaigns, trauma care centres, etc., are some of the other initiatives taken to check the accident rate.

Swedish safety measures

Sweden has a long tradition of vehicle driving safety. The Swedish motor vehicle industry has achieved a world leading status in safety with the enforcement of strict road safety rules and adoption of high vehicle technologies. The guiding principle behind everything made at Volvo is safety.

According to Assar Gabrielsson and Gustaf Larson, founders of Volvo, technological features related to safety have two components: active safety and passive safety. ‘Active’ in simple term means all those features on vehicles which provide safety and minimise injury before the accident. ‘Passive’ refers to all those design features which provide survival space and minimise injuries after the accident.

Many firsts related to passive safety from Sweden are three-point seat belt (Volvo-1958), seatbelts as standard feature (Saab-1962), side impact protection (Saab, 1972), airbags for trucks (Volvo, 1994), world’s first side impact air bags (Volvo/Autoliv, 1995), front underrun protection system, (Scania, 1996), ISA/SRV/Aug 2008, inflatable curtain for side impact head protection (Volvo/Autoliv, 1998), first active head restraint (Saab, 1998), first anti-whiplash seat (Volvo/Autoliv, 1998), and whiplash protection system for rear-seat (Autoliv, 1999).

Current Technologies aim at saving lives through crash safety improvement features. Futuristic Trends will be aiming at moving the emphasis from passive to active safety systems with a focus on preventing the problems from arising and minimising traffic-related fatalities / injuries by developing smart technologies and new IT systems, roadholding and crash safety characteristics for cars and CVs; and intelligent vehicles and road infrastructure systems for users.

With this long safety tradition, Sweden has further consolidated its position by taking unique initiatives like the joint research unit for vehicle and traffic safety, world class collaboration to save lives, research conducted in areas like pre-crash, crash, post-crash and integrity safety, new competence center for vehicle safety systems and solutions, and industry-university co-operation to promote safety culture.

The Intelligent Vehicles Safety Systems (IVSS) programme is an ambitious plan in which the objective is to migrate from active systems to passive solutions. IVSS handles the driver errors effectively. The Vision Zero in Sweden is aimed at achieving zero fatalities and zero serious injuries on the nation’s roads.

CV cabin design features

The driver’s cabin manufactured and supplied by the Swedish majors, Scania and Volvo, have unique design and technology features with high tensile steel cage, steel bumper, front under-run protection system, large glass area with tilt for all-round visibility, large mirrors, excellent lightings, etc., to provide safety.

Some of the internal crash safety features for the cabin are energy absorbing steering wheel, fire-resistant trims and upholstery, knee level softness, stronger A-post, special pedals, adjustable seating systems, good ergonomic dash boards, convenient control positions, climate control and lower noise. These design features provide excellent passive safety in the event of an accident. Anti-lock brake (ABS) and electronic stability programme (ESP) are the additional features which will minimise accidents.

All manufacturers of truck cabins in Sweden design, manufacture and integrate the driver’s cabin on trucks so that they strictly meet the cabin safety standards. For the front end impact test, a pendulum weighing 1250 +/- 250 kg and made of 600 mm cylindrical shape (as per SS 2564 Type A) is used, and the cabin should meet 29.4 kJ impact energy levels. After the test, the driver’s cabin should remain intact on chassis, and all doors should remain closed.

As per Swedish regulation, vertical load of 147 kN is exerted on the roof of the cabin to test its strength and rigidity. After the test, the driver’s cabin should remain intact on chassis. All doors should remain closed, and there should be survival space created inside the cabin.

During the rear impact test, a pendulum weighing 1250 +/- 250 kg and made of 1600 mm x 500 mm rectangular shape (as per SS 2564 Type B) is used to exert impact at the rear of the cabin, and the energy absorption should be 29.4 kN per Ton of Vehicle mass. After the test, the driver’s cabin should remain intact on chassis. All doors should remain closed, and there should be survival space created inside the cabin for manikin created inside the cabin without any contact.

With a strong focus on safety, Swedish vehicle manufacturers have to meet an additional requirement called barrier crash test. Here full frontal collision is given for the truck without any offset and the vehicle travelling at 30 kmph speed under unladen condition. After the test, all doors should remain closed and the driver’s cabin should also remain intact on chassis.

The major difference between the ECE R29 and the Swedish test is that in ECE regulation the frontal impact energy level is 45 kJ, whereas in the Swedish barrier test the approximate level of energy is 260 kJ. All the tests are performed at the shortest and the longest cabin.

Indian CMVR & safety road map

Traditionally Indian CV manufacturers have been supplying either basic cowl or floor with front end structure for driver’s cabin on which various body builders would add rear walls, side walls and the roof to complete the cabin. In fact, cabins made of wood were also quite popular for a long time as they provided effective weather insulation during summer.

SIAM has been working very closely with all stakeholders to finalise a road map for automotive standards, including advanced safety features. Vehicle manufacturers have been following automotive industry standards which are generally in line with the ECE regulations.

In 2003, as a first step, India’s road safety journey started with various measures and technical features which included seat belts, lightings, rear view mirrors, improved braking systems, etc. Subsequently, by 2005, more regulations were introduced. In regard to specific safety standards for driver’s cabin in future, all CV cabins must be tested and type-approved for survival space as per AIS-29.

There are passive safety standards which define the requirements in terms of safety belts, seat belt anchorages, head restraints, fuel tanks, etc. The Automotive Industry Standards (AIS) Committee has been developing detailed technical requirements and standards for driver’s cabins as part of the truck body code to minimise the risk of injury for the occupants or the truck driver.

The AIS-29 is a standard which defines the requirements of survival space for protection of occupants of the cabin of Class N commercial vehicles used for goods transportation. Almost all major guidelines for AIS-29 are generally based on the ECE R-29 regulations. The important safety standards will be implemented from October next.

Similarly, AIS-031 relates to the superstructure strength of large passenger vehicles in which test methods have been defined for roll-over tests, pendulum tests, strength verification, etc.

AIS-029 and ECE R-29

During the test, the Manikin is used to verify the details. It is secured to the driver’s seat which is placed at the rearmost position. The cabin is fitted on the chassis.

In the front impact test, a swing bob made of 1500 +/- 200 kg steel and measuring 2500 x 800 mm flat plate is freely suspended, and it is made to strike front of the cabin. The impact energy is measured, and it should be 3,000 mKgf for vehicle of 7,000 mass. For a vehicle with GVW of more than 7,000 kg mass, energy absorption should be 4,500 Kgf.

The roof of the cabin should withstand a static load corresponding to permitted the front and rear axles and not exceeding 10,000 kg. The rear wall of the cabin should be capable of withstanding a static load of 200 Kgf per tonne of permissible useful load. Manikin is used for verifying the survival space.

Bus body code

India has seen a large number of bus body builders who have been fabricating and assembling bus bodies on regular truck chassis based on conventional designs and technologies. Subsequently many established bus body manufacturers entered the Indian market, like Irizar, Neoplan, Marcopolo, Volvo, etc.

SIAM has now worked out the bus body code to define various design and technological aspects for bus body building. These include floor space, driver area, seating systems, seating layouts, aisle for passenger movements, etc.

Auction, a cost-effective means of selling surplus equipment

By Sameer Malhotra, Country Manager - Asia Sub-continent, Ritchie Bros. Auctioneers
Once regarded as the avenue of last resort, auctions are now one of the most cost-effective and efficient means of selling surplus trucks and equipment. The last few decades have witnesed many changes made in fleet management strategies around the world, and since there is an increasing global demand for good equipment, buyers are heading to auctions in droves, looking for good, quality trucks and equipment for their next project.

What is an auction? The process of buying and selling different products by offering them to a crowd, taking bids (i.e., what will people willingly pay for the item) and finally selling them to the highest bidder is known as an auction. The auctioneer has a rapid-fire chant, the crowd is full of excitement, and the items sell in a quick and efficient manner.

An auction is one of the most effective methods for a seller to be able to have a large number of items sold within a very quick turnaround. And for buyers, an auction is a very efficient way to buy a number of different items, all in one location. The cross-industry selection of equipment all in one place is something that is very enticing to people who are interested in buying trucks and equipment.
All sides of the gavel

The auction method sets itself apart from other methods of buying and selling by gathering items from many different sellers or many different items from one seller in one place in order to sell them through a competitive bidding process at an appointed time.

At an unreserved auction where there are no minimum or reserve bids and everything sells to the highest bidders on auction day, prices are not set by the sellers but are set by the crowd during the competitive bidding process. It ends up being a fair process for both buyers and sellers, as everyone is treated equally and on an “even playing field.”

However, some auction companies do not hold absolute or unreserved auctions, and they will place “reserves” or “minimum bids” for the items being sold (see “reserved auction” in the Talking in auction terms section). It’s very important that you find out ahead of time which type of auction company you are dealing with.

The competitive bidding process provides one of the primary benefits of selling by auction – allowing buyers to take control of the process and the prices at which items are sold. Buyers travel all over the world to attend unreserved truck and equipment auctions because they know it isn’t a waste of time, that the items will be sold on the auction day to the highest bidders regardless of price. They are treated fairly and on an even playing field with every other interested buyer at the unreserved auction.

At the end of the auction, due to the amount of competitive bidding activity from all over the world, sellers of equipment receive the global fair market value for their items and don’t need worry about local selling conditions.
It is also the certainty of the unreserved auction method that attracts both buyers and sellers to unreserved auctions. Both know that everything will be sold on the auction day. Sometimes more than 1,000 items are sold in one day due to the quick chant of the auctioneer. No time is wasted on auction day so that items sell quickly and accurately.

Talking in auction terms

The auction industry, much like other mechanisms of exchange, has its own vocabulary and, for that matter, language. It is important to have a basic fluency in, and an understanding of the language of the trade and the special words used before becoming involved in the auction world.

Auctioneers are marketing professionals well versed in the field. They are detail-oriented, technology savvy and leaders in their community. As they improve through experience and become more knowledgeable in the industry in which they practice their trade, auctioneers become more valuable to both buyers and sellers. Many auctioneers attend auction school to learn their trade and then become licensed in their profession.

The practice of determining the value of an item or service is referred to as an “appraisal.” In simpler terms, and in auction terms, appraisal provides an estimate of what an item should sell for, based on various factors (e.g., state of the market, condition of the item, age or model). A global auction company is often the best source for appraising equipment, due to its knowledge of what similar items are selling for in various economies around the world.

Usually a raised horizontal surface or platform on which the auctioneer will display the item being sold. The concept of “auction ramp” has changed in recent years with technological developments, allowing for a virtual auction ramp or a simulcast auction. Simply put, ‘bid’ is a price offering for an item by a potential buyer at an auction. Simply put, ‘bid’ is a price offering for an item by a potential buyer at an auction. The winning bid is the highest price offered for an item.

The bid catcher assists the auctioneer in catching bids when there is a large crowd of bidders at the auction. The bid catcher will position him or her within the viewing range, allowing the auctioneer to not miss any bids coming from the crowd. The seller becomes a ‘consignor’ when a contractual agreement is signed with the auctioneer in order to place an item owned for sale during an auction. The consignor places the item owned in the hands of the auctioneer while retaining ownership until it has been sold on auction day. Dummy bid is also referred to as a “ghost” or “secret” bid. The consignor may place the dummy bid in order to raise the price of their own item during a sale. Buyers would do best to deal with auction companies that do not allow this type of practice.

Sets of goods or a single item are referred to as “lots” in an auction. Each lot is often numbered to facilitate the bidding process. Minimum bid is the smallest amount that can be bid by a buyer at a reserve auction. At unreserved auctions, there is no minimum bid.

An unreserved or no reserve auction is often referred to as an absolute auction. This is because items will be sold, regardless of price, to the highest bidders on auction day. To outbid is to offer a higher price or make a higher bid than another person. The opening bid is the starting bid at an auction. At an unreserved auction, the opening bid is started by the crowd.

The proxy bid is one bid placed prior to an auction by an interested bidder who will not be present to make his or her bid(s) in person. Once an interested bidder places a proxy bid, the auctioneer will increase the price at the point of sale where the bid has the ability to increase the offer. A proxy bid is often referred to as an “absentee bid.”

The reserve price is a price set by the seller that buyers must meet before the seller is obligated to sell. This approach is more commonly used when sellers don’t want to sell their item below a certain price.

As you can see, an auction is more than just another method of selling. It is a mechanism of buying and selling goods or services through a competitive bidding process that allows buyers to take control of the prices while instigating higher offerings in the spirit of competition. And although an auction may seem complex, it is a very easy way for both buyers and sellers to participate.

Most of the complexity of an auction actually takes place behind the scenes, days and weeks before the auction event actually takes place. There is quite a bit of preparation before an auction by the auction company, so that on auction day it is a smooth process for everyone involved.
While auction companies and auctioneers differ in the services offered, and all have different capabilities within their structure and establishments, most try to provide some of the basic services that form part of the auction process. Every item sold at an auction should be subject to a thorough evaluation by the auction company. Thorough inspections are done to provide the seller with an estimate of what the fair market value is for each item.

Advertising

Part of the auctioneer’s responsibility is to make sure that as many people as possible know about an upcoming sale. This means advertising in fliers, brochures, newspapers, radio, the web and sometimes even television. An auctioneer with a long history in business has the ability to market to a large customer list – customers that have asked to be kept informed of all upcoming auctions since they are serious buyers. The more people who bid at the auction the better the results.

All items need to be looking their best on auction day to ensure that sellers get the best price for their merchandise. Sometimes all that’s needed is a fresh coat of paint, if anything. Auction companies often provide refurbishing services in addition to their auctioneering and marketing initiatives to help sellers get their items ready for auction.

When most people are looking to buy trucks or equipment, they are looking with a specific purpose or job in mind. They want to buy something that they can put straight to work. That’s why many of them prefer to buy from auction companies that guarantee clear title on the items they have in their auctions. Some auction companies work to resolve ownership issues before the auction, which gives interested buyers more confidence when they bid.

One of the greatest benefits of selling by auction is that you can focus on your business and let the auction company take care of selling your equipment for you. Organized, professional auctions conducted by reputable auctioneers attract large numbers of bidders, ensuring that sellers receive the greatest value for their surplus equipment. Conducting a successful auction is not easy: it requires expertise and resources that can only be gained with time and experience.

Choosing an auction company that takes care of all the details, from advertising to meeting with potential buyers and then collecting money from the new owners, is of great benefit to sellers. These details take up valuable time that could otherwise be spent operating a business. Well-established auction companies have vast resources at their finger tips – from accountants to legal professionals to advertising experts – that can be put to work for you.

Auction trends

In order to stay cost competitive, large companies are selling their idle equipment rather than waiting between projects or keeping equipment past its useful life. Smaller firms are buying and selling their equipment more often, too; they are able to purchase used equipment with production value remaining and still realize a better return when their own used items are sold.

Stronger residual prices at auction help manufacturers realize stronger pricing. Financiers and contractors are also able to focus on what they do best with auctions available to them to manage their fleets or to enter and exit a market.

Auctions have also become an important part of an efficient global market. Many manufacturers, including those located in India, use auctions as a means to launch and distribute their new equipment and make it accessible to thousands of buyers in a variety of industries around the world.

If you haven’t yet attended an equipment auction, as a buyer, seller or even as a bystander, you really should. One of the best ways to watch an auction for the first time is to log onto an auction online. You can spend a small amount of time from your home or office watching one of these equipment auctions and don’t need to travel to attend. Of course, an online auction will never replace the feeling you get when attending a live equipment auction in person – there is nothing like it! But, in the meantime, I recommend you log onto www.rbauction.com and view one of the live auctions in progress. It will help you to understand the process a little more, and it can be done at a time that is convenient to you.


If you are considering buying or selling your trucks or equipment at an unreserved auction, please don’t hesitate to contact me. I can answer your questions and provide you with all the details that you need.

Commercial Vehicles - Radialisation picking up momentum

By Jean Paul Caylar, CEO, Michelin India Tyres Pvt. Ltd.
In an era of global warming and soaring crude prices, an increasing resort is made to tyre radialisation for commercial vehicles with a view not only to saving fuel costs but reducing emission of harmful green house gases and easing pressure on global oil reserves. Radialisation also ensures a longer life for tyres.

This is due to the phenomenon known as lowering rolling resistance. “As the wheel goes round, the tyre is deformed to make contact with the road. All the forces required for acceleration, braking and cornering are transmitted through this contact patch. As its structure is deformed, the tyre components heat up, and some of the energy transmitted by the engine is transformed into heat: this is the phenomenon of tyre rolling resistance.”

Rolling resistance is one of the five forces a vehicle must overcome in order to keep moving. The others are aerodynamic drag that depends on vehicle speed, inertia while accelerating, gravity when moving uphill and internal friction in rotating components.
The challenge of low rolling resistance technology is to maintain a tyre’s performance in other areas, particularly safety and wear life. In today’s truck and bus tyre market, two standards exist. The first is cross-ply, or bias or nylon tyres, which is predominantly sold in India’s truck and bus market today. The body of the tyre called the carcass comprises of layers of rubber-coated nylon or rayon fabric called plies. In a cross-ply tyre, the fabric cords of the tyre criss-cross each other. The major reinforcing materials used are rayon and nylon tyre cords.

The main benefit of cross-ply tyres is the initial purchase cost being lower than a radial tyre. However, there are drawbacks, including faster wear, greater fuel consumption, lower vehicle steering control, and greater heating of tyres necessitating stops when travelling long distances.

In a radial tyre, the casing is composed of only one ply made of cords running from bead to bead at 90 degrees to the rolling direction and radially oriented relative to the centre of the tyre.

The secret lies in the parallel carcass arches and reinforced steel belts, allowing total separation of the sidewalls and crown functions: the sidewall and tread areas function separately and the tread is unaffected by the flexing of the sidewalls. This significantly reduces the rolling resistance of a tyre. This results in the ability to drive much more comfortably at much higher speeds without stopping, better steering control and better tyre wear.

The first truck tyre radial was launched in 1952 though the passenger car radial was patented by Michelin in 1946. The energy range of tyres, specifically designed to lower rolling resistance, were first launched by Michelin in 1992, and currently it is the fourth generation of low rolling resistance tyres.

Another key aspect which is less known is that the tyre actually plays a vital role in a vehicle’s energy consumption. At normal driving speeds, a tyre accounts for 30 per cent or more of a truck’s fuel consumption.

Radial tyres help to boost mileage considerably, and the result is a net saving of up to 10 per cent on fuel bills. That’s not a small amount considering that fuel costs account for up to 40 per cent of the cost of operation for trucks and buses.

In recent tests done on Michelin radial tyres versus bias tyres in different conditions across India, the fuel savings recorded was 4-10 per cent on average. Such a difference in the cost of operations makes it possible to amortize the higher purchasing cost of radials over the life of the tyre, and this therefore becomes a significant advantage of the radial tyre.

Then the next advantage of using the Michelin truck radial technology is that after the tyre is worn out there is some extra rubber provided below the tread, which allows one to regroove the tyre. This enables the tyre to run a further 15-25 per cent. Radial tyres can also be retreaded quite easily. This, in turn, will provide 70-80 per cent more mileage (second life). After the second life the whole cycle of regrooving & retreading can be repeated. This allows one to get a significantly lower cost per km.

Opportunities in India

As India continues its steady economic ascent, chalking up an annual growth rate of around eight per cent annually, one of the key drivers for growth will be the effective and efficient mobility of people and goods. Of course there are restraining factors for radialisation, but at the same time opportunities are plentiful.

Among other factors that limit the pace of radialisation is the road condition. Transport congestion, with stop and go, low average speed, poor average distance per day, etc., are other deterrents. Though there is a lot of progress at the Golden Quadrilateral, major bottlenecks hit inter-State movement of people and goods. Maintenance of certain vehicles, geometry maintenance and size of rims may not be favourable to radials as tyres are to be more sensitive to misalignment. This can create uneven wear and reduce the mileage potential. Further, radialisation may be affected by the rising input and fleet maintenance costs.

On the other hand, opportunities for radialisation start with the legal environment, the right road infrastructure which is being strengthened and improved transportation facilities.

However, overloading used to be rampant everyday in the trucking industry, and regardless of the tyres used overloading will cause tyre damage, shorten tyre life, crack rims, and cause accidents due to poor vehicle handling. Overloading also damages the road infrastructure over time. It was not uncommon in India for a vehicle with a maximum load capacity of nine tonnes to carry up to 13 tonnes. It is estimated that a 30 per cent reduction in the life of the highway.

Now with the Supreme Court’s judgment of November 2005 against overloading of trucks and goods vehicles, it is expected that there will be a lot of re-positioning in different tyre segments, and we can foresee a push towards ‘radialisation’ of truck tyres. The scenario will encourage the trucking industry to increase the use of radials. Greater acceptance and fitment of radial tyres by original equipment manufacturers is expected to bring about the transformation in radialisation of the truck and bus segment in India.

The increasing number of multi-axle vehicles (MAVs) is considered another important factor that will give an impetus to radialisation in the CV segment. MAVs are capable of carrying at least 50 per cent more loads compared to normal trucks. This will help reduce the turnaround time.

An additional need to help with the smooth transition for radialisation is the need to provide the right level of information and training to both dealers and end-users. For dealers, it would mean ensuring that the products are matched by the right level of service and technical know-how. For end-users, generating the right awareness on the benefits and usage of radial products will be the key. For Michelin, this component of personal education will play a vital role in its progress in India.

In India, one of the fastest-growing economies in the world today, radialisation is almost complete as far as the passenger car tyres segment is concerned, and is starting to gain momentum in the truck and bus tyres segments. India’s tyre industry has grown rapidly, and is today estimated to be around Rs. 20,000 crores and a sizable percentage of new investment in India’s tyre industry will be spent on improving the radial tyre segment, both for passenger car, as well as for truck and bus.

The future of radialisation in the Indian tyre industry is widely acknowledged to be promising in the commercial vehicle tyre segment. In any case, progress in radialisation, especially the pace of transformation of the market, will be governed by factors like the road infrastructure improvement, overloading control, radial fitments by original equipment manufacturers, the service network.

And even today, with its ability to last longer and depending on conditions sometimes twice as long as a cross ply tyre, operate without over-heating, and save a significant percentage of fuel cost in the process, the switch to radials may happen faster than anticipated.

More than half of all truck tyres in the world are radial truck tyres, as per Michelin estimates. The Asian rate of radialisation is also up at 50 per cent. Markets like Thailand and China, this radialisation rate is upward of 30 per cent. India alone accounts of seven per cent of the world truck tyre consumption. Nevertheless, in 2005, the rate of radialisation was under one per cent and in today’s time it is conservatively estimated as five per cent. In our mind it is just a matter of time. Since this technology provides tangible benefits to the consumer and addresses his top of mind concerns, Radialisation can only increase. India is today poised to join the radial revolution. This technology will pave the way towards achieving sustainable mobility in the country.

This radialisation drive is closely linked with modernization of heavy vehicle fleets, for this is where the strength of radial tyres ties. Add to that the improvement of the Indian road infrastructures, an area where we have seen significant progress in the last few years, the need for radial tyres will become more and more a necessity rather than a luxury. This is one technology which benefits the individual directly and at the same time helps conserve the environment and precious natural resources. In today’s context we feel these two strong reasons will be the key drivers for Radialisation in India.

With over 115,000 employees and sales organizations in more than 170 countries, including India, Michelin is one of the world’s largest tyre manufacturers. Dedicated to the improvement of sustainable mobility, Michelin designs, manufactures and sells tyres for every type of vehicle, including airplanes, automobiles, bicycles, earthmovers, farm equipment, heavy-duty trucks, motorcycles and the US space shuttle, on 69 production sites in 19 countries throughout five continents. The company also publishes travel guides, hotel and restaurant guides, maps and road atlases and offers electronic mobility support services, on ViaMichelin.com. Research and innovation development is being taken care of in technology centres in Europe, the US and Japan.

For Michelin, the need to innovate and contribute to the improvement of mobility is a part of the organization’s genetic code. Its mission is to contribute to the mobility of people and goods by facilitating greater freedom, safety, efficiency and enjoyment of travel.

Commercial vehicle technologies for BS IV emissions compliance

By Arun Ramachandran, Vice President (Automotive Business), Cummins India
The main purpose of Emissions Regulations is to limit, reduce and control air pollution. Emission control is a function of engine technology, fuel quality and traffic speed (congestion). The objective of clean air is achieved only when all these three come together.

On July 15 the MoSRTH issued the draft notification for the next stage of emissions regulations. According to draft notification GSR 522, effective April 1, 2010, Bharat Stage IV norms will be applicable to 11 metros while Bharat Stage III will be applicable to the rest of the country.

Trucks and buses are predominantly powered by heavy duty diesel engines. Modern diesel engines are lighter and are more powerful, fuel efficient and environment-friendly. Bharat Stage IV diesel engines in 2010 will have particulate matter (PM) emissions that are over 95 per cent lower than the Bharat 2000 (BS 1) diesel engines manufactured in the early part of this decade.
This emission reduction is achieved by a combination of improved diesel engine technology and low sulphur (50 ppm) diesel fuel. Combined with reduced traffic congestion this has the potential to check air pollution dramatically.

Today there are two proven approaches to Euro IV emissions compliance. High pressure common rail fuel injection forms the foundation and is common to either approach. Then, to reduce oxides of nitrogen (NOx) and particulate matter in diesel exhaust, the first option is the selective catalytic reduction (SCR) after-treatment approach and the second is exhaust gas recirculation (EGR) with diesel oxidation catalyst or open filter.

SCR is based on running an optimized combustion in the engine that allows it to operate at more optimal combustion temperatures providing better power, fuel efficiency and lower soot (PM) generation. But this process produces higher NOx. To reduce NOx to levels required by emissions standard, a synthetic urea solution such as Adblue is injected into the exhaust stream. In the presence of a catalyst, Adblue turns into ammonia and carbon-dioxide, which then reacts with the NOx to create nitrogen and water vapour, or 2N2 + 3H2O.

The SCR catalyst also acts to reduce soot to an extent. Thus the SCR process reduces soot or PM in engine combustion and Nox and further PM reduction in the after-treatment system.

Now about cooled exhaust gas recirculation (EGR) + DOC / open filter. Cooled EGR introduces cooled exhaust gas, which is low in oxygen, back into the engine, depriving the combustion event of some of its oxygen. This reduces the combustion temperature and lowers NOx production. The downside is that the lower-temperature diesel combustion is less efficient, so it creates more particulate matter and burns more fuel.

The high soot or particulate matter produced during combustion is reduced using oxidation catalyst or open filter. This process results in significantly increased engine heat rejection. In contrast to the SCR process, this process reduces NOx in the engine and soot in the after-treatment process.

As with all technology comparisons aimed at proving the same solution, there are pros and cons to consider for both the technologies that enable compliance to Euro IV emissions. However, both solutions are proven technologies for markets to choose from.
The accompanying table shows a comparison of both technologies across various parameters.

Manufacturers in Europe have implemented both technologies successfully. European production numbers indicate that vehicles with SCR outnumber those with EGR + DOC/ open filter nearly two to one.

Prior to the launch of Euro IV in Europe, there was concern about availability of Adblue distribution infrastructure. Today nobody even talks about this issue as there are various brands like Dureal, Air1, BlueCat, Greenox, etc., supplied by industrial chemical distribution companies like Univar, Brenntag, J & H Bunn Ltd., Kemira Growhow, etc., in partnership with chemicals manufacturers like BASF and Yara ensuring adequate availability of Adblue.

Euro IV regulations became mandatory in Australia with effect from January last. Even though Australia has very little urea production, and most of its urea requirements are being met through imports, SCR technology has been embraced by the Australian commercial vehicle industry. Industrial chemical distribution companies have taken the lead to install manned and unmanned Adblue pumps at remote truck refuelling sites. These and the tie-ups with OEM networks also have ensured adequate distribution networks for supplying Adblue in Australia.

In India

Effective April 1, 2010, Bharat Stage IV norms will be applicable to 11 metros while Bharat Stage III will be applicable to the rest of the regions in India. This implies that BS IV diesel, with 50 ppm sulphur, will be available in the metros, while BS III diesel, with 350 ppm sulphur, will be available in the rest of the country. As commercial vehicles ply across the country, it will be impossible to ensure that BS IV vehicles fill only BS IV fuel.

The negative impact of repeated filling with BS III diesel can be fairly significant for BS IV engines based on cooled EGR + DOC / open filter technology.

The EGR cooler and other engine components are quite vulnerable to the sulphuric acid nuclei formed during the EGR process. Modern coatings offer a fair degree of protection against this situation. However, long-term durability using diesel with higher sulphur content is suspect.

Multiple SAE papers documented that the effectiveness of the DOC / open filter to reduce soot or particulate matter strongly depends on the soot burden and the engine operating point. Repeated fills with BS III diesel is expected to increase the soot burden significantly, raising doubts about long-term emission stability due to catalyst aging and irreversible adhesion of ash particles.

The durability of the SCR system, on the other hand, is not negatively impacted by the usage of BS III diesel. But the system needs an external reducing agent, Adblue, to function effectively. Key concerns on SCR technology center around availability of Adblue in India and vehicle operator’s effectiveness in refilling it on depletion.

The European and Australian experience suggests that Adblue distribution network is unlikely to be a problem. It is expected that industrial chemical distribution companies will take the lead to distribute Adblue through their channels and / or through the vehicle manufacturer channels.

The bigger issue is to ensure that the vehicle operator takes responsibility for refilling Adblue at required intervals. This can be achieved through a combination of driver warning systems, emissions monitoring system and driver inducement system.

The driver warning system (dashboard indication) informs the vehicle operator that Adblue is low and must soon be replenished. The driver inducement system acts as a back-up by triggering engine shutdown or reducing power to a “limp mode” in case a driver attempts to operate the vehicle without proper replenishment. The emission monitoring system, consisting of a NOx sensor at the tail pipe, measures actual NOx emissions. In case the operator uses diluted reducing agents or no reducing agent the sensor will detect high NOx emissions and trigger action by the driver inducement system.

Thus, in the Indian context, the choice of EGR + DOC / open filter or SCR distills down to a question of balancing two opposing risks, i.e., the risk of reduced engine durability and emissions durability on account of high sulphur / adulterated fuel usage for EGR + DOC / open filter versus operator effectiveness in refilling Adblue for the SCR system.

It is expected that the SCR system, coupled with the driver warning system, emissions monitoring system and the driver inducement system, is a lower risk from the standpoint of engine durability and pollution reduction.

In India, fuel cost is said to contribute as much as 50-60 per cent of operating costs, and SCR delivers better fuel efficiency compared to cooled EGR + DOC / open filter. This tips the balance in favour of SCR as the preferred solution in the Indian context, especially when viewed through the lens of lower risk on engine durability, and emissions durability and better fuel economy.

In different parts of the world, Cummins Inc. has thousands of production engines with both EGR and SCR technologies. With the experience of both technologies operating in different markets, based on the above reasoning, Cummins’ main stream plans are to introduce EIV engines with SCR technology.

Castrol launches CRB Plus and Turbo oils with synthetic technology

Castrol India Ltd. has relaunched its largest selling diesel engine oils, Castrol CRB plus and CRB Turbo, incorporating the synthetic technology. Keeping in line with its position of being a technology leader, the company has once again taken the lead in introducing the synthetic technology in diesel engine oils in the Indian market.

Commenting on the newly launched engine oils, Mr. Shankha Banerjee, General Manager - Marketing, Castrol India, said the commercial vehicle segment in India has seen an upgradation in technology owing to the massive investment and improvement in road infrastructure and adoption of the Euro norms.
The tractor segment is also seeing increased non-farm usage. Both truck and tractor consumers have increasingly started demanding better performance and dependability from their vehicles which at the same time have to work under more and more stressful conditions and varying operating conditions. In such a situation, the engine oil has to provide peak performance, protecting the engine and ensuring superior performance over long periods of time.

Castrol CRB, he said, is one of the most trusted brands with a loyal consumer and customer base build over 75 years since its launch in India. It has provided the cutting edge and relevant technology, which has been consistently upgraded to meet the changing engine and environment conditions. In keeping with this tradition, Castrol is relaunching Castrol CRB Plus and Castrol CRB turbo, incorporating the synthetic technology which ensures greater engine protection and performance.

The synthetic technology helps deliver superior engine protection during start-up and high stress conditions, better engine protection even in extreme temperatures and against soot and related impurities, greater engine cleanliness and smoother running, enhanced fuel efficiency, lower oil consumption and longer drain intervals.
Castrol CRB has completed 75 years in India since its launch in 1932. Over the years, the brand has been constantly upgraded to keep pace with the changing engine technology and environmental conditions. With four sub-brands – CRB Plus, CRB Turbo, CRB Prima and CRB Prima Plus – Castrol CRB has consistently remained the brand of choice for trucks, tractors, buses and jeeps.

Castrol India, in which 70.92 per cent of the paid-up capital is held by Castrol Ltd. of the UK, has grown to become the market leader in the retail automotive lubricant segment. The company which has demonstrated its commitment to Indian consumers by offering world class products, backed by the highest level of customer service, is acknowledged as the technology leader in the Indian lubricants industry.

Growing global market for air spring technology

By Arun Kumar, Managing Director, Firestone Industrial Products - Asia
As we celebrate the 70th anniversary of the first rubber air spring this year, the global community of air spring manufacturers sits on the cusp of exciting growth potential throughout Asia. The economies of China and India especially are booming. India’s GDP growth in 2007-2008 was 9.1 per cent, pushing the national GDP over the $1 trillion mark. Such economic growth vastly increases the demand for new motorized vehicles of all types for transportation of people and goods. It also increases the demand for higher quality and performance from these vehicles.

For this reason, air spring systems for automotive, trucking, off-road and rail applications are quickly gaining popularity among motor vehicle manufacturers in Asia. A vehicle with an air spring suspension provides a much smoother and more comfortable ride than one with the traditional mechanical leaf or coil spring suspension, adding extra safety for fragile cargo. Studies have shown that heavy-load vehicles with air springs also cause less wear and tear on road systems. The benefits from air spring systems are far-reaching.
Simply put, air springs improve the ride and handling of the vehicle by providing cushions of air between the wheels and the frame. The spring assembly comprises an air-filled rubber cord structure that rolls up and down over a plastic or steel piston. As the vehicle travels over a roadway, the spring undergoes jolting bounces and rebounds and absorbs energy from the wheels. This cushioning effect increases the comfort of passengers and the security of cargo.

This article provides an overview of the air springs market in India and a forecast of what lies ahead. First, however, let’s begin with a background of air springs and product innovations over the years.

Firestone Industrial Products designed and patented the first rubber air spring in 1938, and by the 1950 air springs were being used in the US in the suspensions of buses and select General Motors automobiles. Though air springs gained little traction in the automotive industry initially, they made a good penetration into the truck and trailer market in the 1960s, where they are most widely used today.

In the US and Europe, the air springs market reached critical mass in the 1980s, as design and system improvements brought air springs back into the automotive industry for luxury vehicles, and manufacturers significantly strengthened their foothold in the truck and trailer industry. Since then, the uptrend in sales continued.
In the latter half of the 1990s, Firestone and other air springs manufacturers got the opportunity to expand into Asia, with the emergence of growing economies of China and India. Air springs were introduced in India through suspensions for luxury buses. Luxury bus passengers soon became accustomed to smoother air rides, and today air spring suspensions are becoming a standard fitment in most luxury buses made in India, creating exponential growth in demand for the product.

As of 2007, Europe accounted for 52 per cent of the global air spring market for heavy-duty vehicles, and North America accounted for 31 per cent. Asia currently makes up 13 per cent of the market, a figure that is expected to increase to 20 per cent by 2013. The air spring industry is now seeing increased demand in the luxury bus, truck and trailer sectors across Asia from original equipment manufacturers (OEM) – and for very good reason.

The major outcome of the current Asian prosperity is the growth of heavy truck manufacturing in China and India, which along with Brazil, are the decade’s three fastest-growing truck markets in the world. In fact, if current trends continue, China is expected to overtake North America as the world’s largest truck manufacturer in the next three years.

China produced 343,072 trucks last year and India 119,160. Another sign of a thriving economy – infrastructure growth – largely drives India’s growth in motorized vehicle production.

Infrastructure growth

India’s National Highways Development Project (NHDP), a massive government infrastructure rehabilitation project, will produce 66,590 km of new roads and improved existing roads, all waiting for automobile, truck and bus travel. The first phase of the NHDP – the 5,846 km Golden Quadrilateral network of expansive express highways connecting Delhi, Mumbai, Kolkata and Chennai is almost 97 per cent complete (http://www.nhai.org/goldenquadrilateral.asp). Also in progress are Phase II of NHDP, the North-South-East-West Corridor highways (6,647 km); Phase III, involving the upgrading of 4,035 km of national highways; Phase IV, which will widen 6,500 km of existing four-lane highways; and Phase V, which will add 1,000 km of expressways. The estimated expense of this expansive project is $13.2 billion (Rs. 54,000 crores).

With such an investment, it’s certain that the Union Government would protect and preserve this world-class network of highways for as long as possible. One way to do this is by ensuring that heavy vehicles put only minimal wear and tear on roads, as they are typically responsible for 50 per cent of road maintenance costs. Air springs are an excellent solution to this problem.

The Organization for Economic Co-operation and Development (OECD) has reported that the use of air suspensions on motor vehicles increases the pavement life by 15 to 60 per cent, corresponding to increased static load of 4 to 12 per cent. Increased pavement life means significant reduction in road maintenance costs, which often comprise 90 per cent of annual road budgets in OECD countries.

Another factor increasing demand for trucks and air springs is transportation of goods from railway stations to their final destination. India still relies heavily on rail transportation for long-distance freight movement, and there are currently additions being made to its national rail system. Goods are moved at high speeds over long distances by rail, and trucks carry them the rest of the way. Air springs will also be needed on trailers used in inter-modal transport, where a trailer with goods is transported by train part of the way and hooked up to a truck for the remainder of the trip.

Transportation trends

Over the past 10 years, luxury bus passengers in India and China have noticed the difference between a bus with traditional mechanical leaf suspension and one that has an air suspension. Luxury buses with air suspensions provide a more comfortable ride, and bus riders are willing to pay the extra fare to ride on them. And, many more are able to do so, thanks to the thriving national economies. The luxury bus segment has provided a strong entry point for the air spring market into India and China. There is no better way to promote the virtues of air spring suspensions than having vehicle passengers experience these air rides themselves and spread the word.
Once people understand how smooth an air spring-equipped vehicle rides, it is easy to understand the value in air suspensions for shipping fragile goods, such as poultry products, glass and luxury items.

Major market segments

There are five major market segments in Asia where air springs are gaining popularity and will continue to grow in use:

• Truck suspensions – a fast-growing market. As the highway infrastructure grows and more manufacturers and truck repair outlets become educated about air springs, there will be a significant increase in demand from the OEM and the replacement parts sector.

• Trailer suspensions – also growing fast. Air spring-equipped trailers provide much safer transportation for goods than standard spring suspensions and limit wear and tear on roads.

• Cab mounts provide more comfort and less wear and tear, due to reduced vibrations in the cab of a large truck. Growth is slow, as they are still considered to be a luxury item.

• Seat springs provide extra sitting comfort. Though considered a luxury item, this segment is rapidly growing. Air-suspended seats and cab mounts have been identified as a means of reducing driver fatigue and increasing productivity.

• Helper/hybrid springs – these air springs supplement the existing springs to enhance ride quality, enable leveling of the vehicle and improve steering and brake control.

Future of air suspensions in India

With air springs, India has the advantage of adopting a product that has already gone through much improvement and development in other countries over the past 70 years. And, the nation is quickly becoming more technically savvy. With these factors in play, it is certain that air spring suspensions will experience rapid adoption in truck, trailer, bus and inter-modal segments.

In the years to come, air springs will likely have high penetration in trucks, trailers, lift axles, medium-size buses and helper springs for leveling. But the level of growth depends greatly on how well the air spring industry educates its customer base. For instance, highways in India have an extensive network of roadside repair shops for conventional suspensions. It is vitally important that this network be familiarized with repair and maintenance of any new technology products because this network is truly the backbone of the national service infrastructure.

With the current trends in Asia, however, we can expect that the air springs industry will see considerable growth, especially in India and China. Industry forecasts show that in 10 years, 50 per cent of all heavy commercial vehicles in India will have air spring suspensions, and 70 per cent of heavy commercial vehicles will have them in China.

With more and more individuals and companies in India and China experiencing the comfortable rides and enhanced passenger and cargo safety of air spring-equipped motorized vehicles, air springs are sure to become a widespread standard across Asia.