Abilities India Pistons & Rings Ltd. (Abilities India), a leading automotive component manufacturer, has announced the grant of its second patent for its groundbreaking High-Pressure Die Casting (HPDC) process. This innovation is set to significantly enhance the efficiency and sustainability of piston manufacturing, promising substantial economic and environmental benefits.
The newly patented HPDC process enables a reduction in the weight of pistons for two- and three-wheelers by 10-15%, resulting in an annual aluminum saving of 307.5 tons based on the current production of 20 million vehicles. This saving is projected to rise to 461.25 tons annually by 2030, with corresponding carbon emission reductions of 920 tons per annum currently, increasing to 1380 tons per annum by 2030.
Abilities India plans to leverage this technology both in domestic and international markets while developing critical components to support the self-reliance goals of major Indian Original Equipment Manufacturers (OEMs). The company reported a notable revenue of Rs 128 crore in FY24 and is poised for substantial growth driven by its technological advancements. It aims to achieve a top line of approximately Rs 225 crore by FY2026 and increase its EBITDA from 14% in FY2024 to around 16% by FY2026.
To support this growth, Abilities India will double its R&D team size and increase R&D fund allocation to 3% of revenue. The current manufacturing facility, spanning 5 acres with a built-up area of 14,153 square meters, will be expanded by an additional 3,000 square meters in FY25/26 with an investment of Rs 20 crore, adding to the Rs 17 crore invested in FY24.
Traditionally, pistons for gasoline and diesel engines are manufactured using the Gravity Die Casting (GDC) process, which is optimized for mass production but limited by thicker wall thicknesses and higher machining allowances. In contrast, Abilities India’s HPDC process uses high pressure to shape molten metal within a mold, allowing for intricate contours and precise geometry with minimal machining. This innovation applies to various piston types and represents a significant advancement in engine component technology, meeting stringent emission regulations for both 2-stroke and 4-stroke engines. The HPDC process addresses the automotive industry’s evolving needs for lightweight, high-performance components and tightening emission standards.
Sunil Arora, Chairman and MD of Abilities India Pistons & Rings Ltd., expressed his enthusiasm for the company’s achievements, stating, “At Abilities India, we are dedicated to pioneering research and technological advancements within the auto components industry. Our second patent underscores our unwavering commitment to innovation and sustainability in automotive manufacturing. With the development of this cutting-edge manufacturing process, we are improving engine performance and actively reducing emissions, thus shaping the future of automotive technology. This milestone reinforces our position as leaders in sustainable and efficient solutions for the global mobility domain.”
Tushar Arora, Joint MD & CEO of Abilities India Pistons & Rings Ltd., added, “Our newly patented High-Pressure Die Casting process is a game-changer for the automotive industry. By reducing piston weight, we are enhancing fuel efficiency and engine performance while also cutting down on material usage and carbon emissions. We are excited about the transformative potential of this technology.”
This strategic focus on innovation and sustainability positions Abilities India at the forefront of the automotive component industry, ready to drive significant revenue growth and contribute to a greener, more efficient future.
