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

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Ashok Leyland, one of the leading commercial vehicle manufacturers in the country, has opened a new integrated manufacturing facility in Lucknow, Uttar Pradesh.

The greenfield facility, located near Lucknow Airport in Sarojini Nagar, was inaugurated by Yogi Adityanath, Chief Minister of Uttar Pradesh, alongside Union Ministers Rajnath Singh and H D Kumaraswamy.

The 70-acre site is designed to produce 5,000 vehicles annually, with a primary focus on electric buses and other green mobility solutions. The facility employs a workforce predominantly from Uttar Pradesh, including a high percentage of women. To support its sustainability goals, the plant features rooftop solar panels, energy-efficient lighting and zero-discharge water systems.

Dheeraj Hinduja, Chairman, Ashok Leyland, said, "The inauguration of this new plant marks the beginning of an important new chapter for Ashok Leyland in the vibrant state of Uttar Pradesh. Our Group remains deeply committed to unlocking further opportunities that drive economic growth, create meaningful employment, and foster long-term prosperity in the region. This manufacturing plant reaffirms our resolve to help shape the future of India’s commercial vehicle industry, and we are confident that it will make a strong contribution towards employment generation while advancing sustainable mobility. With this new plant, we are preparing ourselves for the future and take one step further to achieve our Net Zero emission goals."

Shenu Agarwal, MD & CEO, Ashok Leyland, said, "As one of India’s largest and most progressive states, Uttar Pradesh has demonstrated a strong and consistent commitment to environmental responsibility and sustainable development, making it a natural partner in our green mobility journey. This coupled with Ashok Leyland’s ambition to achieve Net Zero by 2048 has been a key catalyst for establishing this state-of-the-art facility in Uttar Pradesh. Equipped with most modern technology and high levels of automation, the plant reflects our focus on world-class quality and innovation. With a strong emphasis on electric buses, this facility marks a significant step towards building a cleaner, future-ready mobility ecosystem for India.”

The plant's logistics are managed using battery-operated vehicles to maintain its status as a green facility. This expansion aligns with Ashok Leyland's target to reach Net Zero emissions by 2048 and supports the state of Uttar Pradesh's transition toward electric transportation.

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Bharat Forge and Germany-based Agile Robots have agreed to explore a collaboration to develop AI-driven robotics and industrial automation. The partnership combines Bharat Forge's domain expertise with Agile Robots' automation solutions to deploy technology for the automotive, healthcare, and consumer electronics industries.

The agreement focuses on civilian industry and manufacturing. Under the Memorandum of Understanding (MoU), the companies will co-develop and offer solutions in manufacturing, industrial CPG and logistics for markets in India and Southeast Asia. The partnership also aims to develop vision and AI-based robotic systems to enable autonomous ‘dark’ factories.

Amit Kalyani, Vice-Chairman and Joint Managing Director, Bharat Forge, said, “This strategic collaboration with Agile Robots is a reinforcement of Bharat Forge’s ambition to provide state-of-the-art intelligent robotic and automation solutions across multiple industries while driving manufacturing efficiencies at home. Manufacturing in India is on a steep growth path, and I am very excited that with Agile Robots we are going to deploy bespoke, modular and intelligent automation solutions across the sectors.”

Rory Sexton, Executive Director, Agile Robots, said, “By partnering with Bharat Forge, Agile Robots is strengthening its position in India's rapidly growing manufacturing sector. Combining Agile Robots’ proven leadership in AI driven robotic automation with Bharat Forge’s sectoral expertise will allow us to improve the efficiency and precision of entire production systems.”

The collaboration intends to set up capabilities for bespoke solutions while utilizing existing Agile Robots technology. By integrating AI into production systems, the companies aim to improve precision and efficiency across manufacturing sectors in the region.

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Hindustan Zinc and Silox India have expanded their long-term collaboration to focus on industrial decarbonisation and the development of sustainable supply chains. As part of the agreement, Silox India has adopted EcoZen, a low-carbon zinc brand produced by Hindustan Zinc, for use across its manufacturing operations. This integration is intended to reduce the carbon footprint of zinc-based chemical products while maintaining existing quality standards.

EcoZen is manufactured using renewable energy and has a verified carbon footprint of less than one tonne of CO2 per tonne of zinc. According to the company, this is approximately 75 percent lower than the global industry average. The material offers full traceability, allowing downstream users to account for the environmental impact of their inputs. When used in galvanising, EcoZen can prevent approximately 400 kilograms of CO2 emissions per tonne of steel compared to conventional zinc.

Hindustan Zinc, a Vedanta Group company, supplies materials to various sectors including infrastructure, automotive and renewables. The company is a member of the International Council on Mining and Metals (ICMM) and has prioritised the reduction of Scope 3 emissions for its clients. Silox India, which specialises in inorganic chemistry and non-ferrous metal derivatives, will use EcoZen to support its environmental, social, and governance (ESG) targets.

Arun Misra, Chief Executive Officer & Whole-time Director, Hindustan Zinc, said, “Decarbonisation at Hindustan Zinc is not limited to our own operations; it extends to how our products are used across industries. EcoZen represents a step change in how zinc can support cleaner manufacturing. By partnering with customers like Silox India, we are enabling the wider adoption of low-carbon solutions at scale.”

Prakash Raman, Managing Director, Silox India, said, “Integrating EcoZen into our manufacturing processes allows us to lower embedded emissions across our product portfolio while continuing to deliver high-performance solutions to our customers. This partnership demonstrates how upstream innovation can accelerate sustainability outcomes downstream.”

The partnership aligns with the increasing demand for low-carbon materials in the automotive and infrastructure sectors. EcoZen is supported by life-cycle assessments and globally recognised ISO and REACH certifications to ensure transparency and compliance with environmental regulations.

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Maruti Suzuki India, the country’s largest passenger vehicle manufacturer, has reported its highest-ever annual production with 2.25 million units produced in CY2025.

This also marks the second year the automaker surpassed the 2 million units production threshold. The total includes vehicles destined for the domestic market, exports and supplies to other original equipment manufacturers (OEMs). The Fronx, Baleno, Swift, Dzire and Ertiga were the five models with the highest production volumes during this period.

The company began operations in 1983 at its facility in Gurugram and has since expanded its manufacturing footprint to include sites in Manesar and Kharkhoda, alongside the integration of its Gujarat plant.

At present, Maruti Suzuki India produces 17 models and 650 variants. To address future demand in India and abroad, the firm intends to increase its total production capacity to 4 million units per annum.

Hisashi Takeuchi, Managing Director & CEO, Maruti Suzuki India, said, “This record production is a result of the dedication of our employees and the strong synergy that we share with our supplier partners. A high degree of localization has enabled us to achieve such scale while maintaining world-class quality, highlighting the strength and global competitiveness of India’s automotive manufacturing ecosystem. We remain committed to expanding our manufacturing footprint and strengthening India’s automobile manufacturing capabilities in line with the Government of India’s ‘Make in India’ initiative.”

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