Kotak Alternate Asset Managers Limited invests in Ace Designers Limited to support Ace Designer Limited’s plans for business expansion, capacity enhancement and strengthening its global presence. 

Ace Designers Founded in 1979 by three engineers from the Central Manufacturing Technology Institute (CMTI), as a design consulting company went on to establish AceMicromatic Group. With the amalgamation of Ace Designers, Ace Manufacturing Systems and Micromatic Machine Tools, the new organization Ace Designers Limited is India’s largest manufacturer of CNC turning centres and machining centres. With an anticipated annual turnover exceeding INR 2400 Cr in FY24-25, ADL can manufacture 8,000 turning centres and 3,400 machining centres. ADL has established a market presence across Asia, Australia, the Middle East, North and South America, and Europe and has 25+ years of market leadership in CNC Turning & CNC Machining Centers in the domestic market. 

Ace is appreciative of the role played by EY in this amalgamation & investment execution journey bringing in their expertise and systemic approach and thanking them for their diligent efforts SG Shirgurkar Promoter, ADL said “This pivotal partnership with Kotak Alts will be a powerful catalyst, accelerating our investments in technology, capacity, and talent. It strengthens our commitment to becoming a significant global player and amplifies our nation-building efforts through advanced manufacturing and skill development. We are excited about the transformative synergies and our enhanced ability to serve our customers and achieve our long-term vision.” 

 TK Ramesh Managing Director, ADL said “In line with our many firsts, we are working diligently and are on the path to become a global machine tool company from India with a strong belief that flexible and competitive manufacturing will fill in technology gaps. With this partnership, we take a step ahead to play in both the high technology market and the standard volume market.” 

Eshwar Karra, Managing Partner Kotak Alts, said, “We are bullish on the Indian manufacturing theme and the Ace team, with its entrepreneurial and engineering first spirit, has been working on building India’s manufacturing eco-system for the past 4 decades. With CNC machines being one of the critical pillars of the manufacturing industry, we are excited to participate in Ace’s growth story and contribute to such an important aspect of the manufacturing economy.” 

 Rahul Chhaparwal, Partner at Kotak Alts, expressed optimism about the partnership, stating, “Ace is on the verge of substantial growth with several key milestones approaching. The Company is embarking on a significant expansion journey and our investment in Ace is in line with our philosophy of partnering with high-quality, innovative and customer-centric businesses run by experienced management teams.”  

India faces a significant challenge in ensuring occupational health and safety for workers, with 80% of the estimated 465 million-strong workforce not protected by the existing health and safety legal framework. Suresh Tanwar, Head of Audit and Consultancy – India, has highlighted the alarming number of deaths and injuries in India’s manufacturing sector. 

Manufacturing is central to the balanced, sustained growth of any economy. It creates jobs and has a multiplier effect on the economy. Considering the focus on the manufacturing sector, it is important to scrutinise the existing occupational health and safety practices. Deficiencies in workers’ health and safety could prove costly in the long run, and any growth in manufacturing must entail a clear practical system to ensure occupational health and safety for workers.

India is seeing on average three deaths and 11 injuries every day due to accidents in registered factories, as per a recent media report. As many as 3,331 deaths were recorded between 2018 and 2020 as per the Ministry of Labour & Employment Directorate General Factory Advice Service and Labour Institutes (DGFASLI) in November 2022, the report states. These figures don’t even account for the number of injuries and fatalities among people employed in the unorganised sectors. The alarming figures reiterate the need for inculcating safety as a core value in organisations.

India’s efforts to become a global manufacturing hub are aimed at promoting investments and innovation. However, fatalities and injuries are common, with 80% of the workforce not protected by the existing health and safety legal framework. Workplace deaths in India are 20 times higher than in the UK, with an estimated 48,000 work-related deaths each year. In contrast, in the UK, employers have a legal duty to assess risks to workers’ health and safety.

Workplace health and safety in India

In India, in contrast, many employers do not show enough care for the health and safety of their workers. Daily wage workers in India are poorly trained because their employers know that they are easily replaced. They are not given adequate training by the contractors who, recognising the temporary status of their workers, do not invest in their training or their health and safety.

An NGO released a report on worker accidents in the automobile sector. They found that most of the injured were untrained helpers. According to the NGO, press shop assistants and operators need a minimum qualification of up to Class VIII. They also need a licence or training in basic press shop housekeeping skills and safety. However, the report found that helpers with little or no training were appointed. They were also found to be overworked and denied overtime. About 51 per cent reported putting in 12-hour shifts. This also leads to accidents.

In addition to the high risk of being killed or seriously injured in site accidents, factory workers in India face the risk of developing serious and often fatal health conditions and diseases due to exposure to various health hazards. These include musculoskeletal disorders (such as serious back injuries), caused by unsafe manual handling of loads; injuries and fatalities due to falling from height and disabling electrical shocks, burns, and often fatal respiratory diseases, such as silicosis from exposure to dust. 

Workplace accidents can have major consequences for a business in terms of the lost time and effort spent dealing with the aftermath of an accident, such as lost management time, reduced productivity, and a negative impact on organisational culture and morale. It also affects the family of the employee who has had an accident. The financial burden can often push the family into poverty.

Good health and safety management is also good business. If an organisation looks after the health, safety, and welfare of its workers, it will be more productive, and this will help the business to be more successful and sustainable.

There is a great need in India for a culture change with regard to workplace health, safety, and wellbeing. Legislation plays an important role in helping to bring about this change, but safety culture needs dedicated leaders who will champion it every day and at all levels. The leadership should regularly remind all workers, through forums such as team meetings, that the health, safety, and welfare of the company’s employees, contractors, suppliers, and customers are critically important to the business.

Frontline workers, supervisors, and managers are the people who understand whether the health and safety management procedures are working or not, so leaders need to create an open environment where workers feel they can voice their concerns, issues, challenges, and ideas around health and safety. Senior management should foster a culture of psychological safety where employees can express themselves freely. This is also an important factor. Employees will know their employers are open to suggestions for improving health and safety, and workers should be given access to senior people to make those suggestions.

There are Indian business leaders who are willing to stand out and show that safety and health are crucial parts of what they do. Industrial safety is an undying mission and top priority for India as a manufacturing powerhouse. Therefore, India needs more safety leaders to emerge and make a difference if it wants to be recognised as a truly global manufacturing hub.

The Customer Experience Centre is equipped with advanced testing, inspection, and quality solutions.

Blue Star Industrial Solutions, a Blue Star Engineering & Electronics Limited division, inaugurated the Customer Experience Centre (CEC) in Pune, Maharashtra. This pioneering facility brings a comprehensive range of quality control and testing solutions — spanning Non-Destructive Testing (NDT), Material Testing, Environmental Chambers, and Metrology — under one roof, offering an immersive and interactive platform for industries across India.

The inauguration ceremony was attended by Vir Advani, Chairman and Managing Director of Blue Star Limited; Arun Rajan, Chief Human Resources Officer of Blue Star; Prem Kalliath, CEO of Blue Star Engineering & Electronics Limited; Rajesh Sahu, COO of Industrial Solutions; and other senior leaders. Their presence marked the formal opening of the facility but also underscored the company’s unwavering commitment to innovation, customer-centricity, and engineering excellence.

The newly established CEC is designed as an interactive hub where customers, partners, and industry professionals can experience live demonstrations, engage in application-driven discussions, and collaborate on building future-ready solutions. Blue Star Industrial Solutions aims to empower industries to achieve the highest standards of quality, reliability, and compliance by offering an integrated view of the latest in testing and inspection technologies.

Speaking on the occasion, Prem Kalliath, CEO of Blue Star Engineering & Electronics Limited, said, “The Customer Experience Centre in Pune reflects our commitment to being a true partner in our customers’ journey towards quality excellence. By enabling a firsthand experience of our solutions in action, we aim to foster deeper collaboration, accelerate innovation, and co-create solutions that meet the dynamic needs of Indian industries.”

The facility showcases Blue Star Industrial Solutions’ broad expertise across Non-Destructive Testing (NDT), Material Testing Systems, Environmental Simulation Chambers, Metrology, Robotic Inspection Systems, and Accredited Calibration and Inspection Services. Customers visiting the CEC can experience live application trials, explore customised testing setups, and engage with Blue Star’s technical experts to address their unique quality and compliance challenges.

Adding to the significance of the launch, Rajesh Sahu, COO of Industrial Solutions, stated, “Our new Customer Experience Centre is more than just a showcase; it is a platform for engagement, innovation, and co-creation. We want our customers to witness not just the breadth of our portfolio but the depth of our engineering and service capabilities. It is an open invitation for industries to explore, collaborate, and build the next generation of quality solutions with us.”

The launch of the CEC aligns with the Indian Government’s ‘Make in India’ initiative, which aims to bolster Indigenous manufacturing capabilities. It further strengthens Blue Star Industrial Solutions’ position as a trusted partner in industries ranging from automotive, aerospace, energy, and infrastructure to electronics and heavy engineering.

Having served Indian industries since the 1960s, Blue Star Industrial Solutions has built a legacy of delivering reliable and innovative testing, measurement, and inspection solutions. With the Customer Experience Centre in Pune, the company reinforces its commitment to advancing industrial excellence and supporting customers with future-ready technologies that meet the most stringent global standards.

As industries across India and beyond strive to enhance quality assurance and compliance frameworks, Blue Star Industrial Solutions’ new CEC is a vital catalyst, making excellence more accessible, experiential, and impactful.

The vision to create India as a viable manufacturing centre compared to others requires great effort and strategy. India is lauded with MSME players in all sectors. India’s industrial landscape is lauded for its vibrant ecosystem of MSMEs, which is spread across various manufacturing domains. In this special feature, OEM Update shines the spotlight on CNC machines and the role of MSMEs in this segment. We delve into the challenges these enterprises face and explore practical solutions to overcome these barriers, guided by insights and perspectives from industry experts, where each expert covers a vital element of CNC manufacturing.

Innovation is reshaping industries across the globe, and Indian manufacturing is riding this wave with remarkable momentum. India is home to over 73 million MSMEs, employing more than 120 million individuals. These enterprises contribute nearly 30% to the national GDP, accounting for over 35% of the country’s manufacturing output. MSMEs are thus central to inclusive industrial growth in India. 

Large players have long embraced CNC technologies, but the MSMEs are now making bold moves. CNC machines are equally vital for small and medium enterprises seeking to automate production, enhance precision, boost repeatability, and reduce costs. However, most small-scale manufacturers face numerous challenges, ranging from financial constraints to inadequate skilling. Industry experts in CNC machinery shared insights on how MSMEs can make a mark with CNC technologies and offered practical tips to overcome these common challenges.

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AROOP Sarkar, Industrialisation Engineer, John Cockerill

New Innovations

AI-driven predictive maintenance in CNC (Computer Numerical Control) machines is rising. As industries pivot from reactive fixes to proactive strategies, AI helps maintain, operate, and optimise CNC machines for automotive, aerospace, and precision engineering.

AI-enabled CNC machines use vibration, temperature, and sound sensor data to predict potential failures before they occur. This minimises unplanned downtime, cuts maintenance costs, and improves equipment life. AI provides real-time, condition-based servicing instead of fixed maintenance intervals, enhancing efficiency and effectiveness in the maintenance process.

With IoT integration, small and midsized manufacturers in Tier-2 and Tier-3 cities can access advanced diagnostics remotely—an essential shift post-COVID. For example, companies in Maharashtra and Tamil Nadu are piloting AI-integrated solutions like Bosch’s i4.0 India to modernise older CNC systems.

Tomorrow’s CNC machines will do more than cut and mill—they’ll adapt and optimise themselves. AI-powered CAM intelligent software is automating toolpath generation for precision and efficiency.

Self-learning machines will improve with every job, learning from previous runs to deliver higher quality. The integration of edge and cloud analytics allows real-time decision-making at the machine level, enabling long-term improvements through cloud-based insights.

The AI vision system automates on-the-fly quality checks, thereby reducing defects and streamlining production processes.

As big players go digital, India’s MSMEs can stay competitive by being agile, collaborative, and tech-savvy. Collaborative clusters are established to share advanced machinery and inspection tools with nearby SMEs through alliances or government programs like MSME SAMARTH.

Lean Automation involves retrofitting legacy CNCs with affordable sensors or cloud platforms for immediate ROI. Government support can be provided through schemes like CLCSS, ZED, and NITI Aayog’s AI framework for financial and technical assistance and partners with NSDC or IIT-Madras programs to train workers in digital CNC operations.

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Apurb Kumar Nayak, Industrial Automation & Robotics Faculty, Tata Indian Institute of Skills 

Financing Challenges

For SMEs, adopting CNC machines requires strategic financing—whether through leasing, tapping into government subsidies like MSME schemes, or collaborative shared-access models—to mitigate the upfront costs. Achieving ROI hinges on operator training to minimise errors, consistent preventive maintenance to extend machine lifespan, and optimised workflows through batch production, waste reduction, and data analytics.

I always recommend starting with a single machine—prove its profitability first, then scale up gradually. As a CNC trainer at TATA Indian Institute of Skills, I work closely with SMEs to design training programs beyond machine operation. We focus on CNC, maintenance, and lean practices, ensuring machinery becomes profitable.

Indian SMEs face challenges in adopting advanced CNC machines due to high capital costs, limited technical expertise, and apprehensions about operational disruptions. Many of these lack skilled operators, which leads to underutilisation and maintenance inefficiencies.

Bridging this gap requires a dual strategy. SMEs can collaborate with training institutes to develop customised upskilling programs focusing on advanced manufacturing, precision machining, and preventive maintenance. Concurrently, exploring financing models like leasing or government subsidies can mitigate financial barriers.

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Sanjib Chakraborty, Managing Director, Hurco India Pvt., Ltd.

Collaboration of Large Players and MSMEs

Innovations in CNC machines are now focused on eco-friendly solutions, high-speed machining, improved software and digital technologies. IoT technology and advanced sensors enhance machine efficiency, while the rise of additive manufacturing is opening new avenues. Automation and AI-powered machine monitoring are streamlining operations and ensuring predictive maintenance.

Small-scale manufacturers can sustain themselves in an ecosystem dominated by large-scale industries through strategic partnerships and collaborations, continuous skill development, and securing ISO certification to access new markets and build trust. Innovating new designs and prototyping, establishing a strong digital marketing and online presence, and using cost-effective NC machines to boost productivity are essential. Their agility in decision-making and ability to build strong client relationships give them a competitive edge.

Encouragement for local and foreign firms to set up operations in India, along with R&D support from institutions like CMTI, is driving innovation. Skill development programs, technology transfers with global CNC leaders like BFW, Jyoti, and LMW, and dedicated support for MSMEs are also pivotal to this effort.

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Mohammad Irfan, CNC Expert, Saudi Mechanical Industries

Growth of small-scale manufacturers

The most important thing that MSMEs need to accomplish is make to the delivery on time. Small manufacturers must also pay close attention to quality. By consistently focusing on these two factors—timely delivery and product quality—they can grow steadily, earn customer trust, and reach the heights of success in a competitive market.

All the CNC machine companies have made good progress so far.  Innovations like Automatic offset reading, automatic material diameter calculation systems, and Automatic program generating systems are expected. Such advancements will benefit the industry by saving time, reducing manual errors, and improving overall efficiency in machining operations. If some such innovations happen, then the industry will get many benefits.

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Abhishek Suchak, Scientist, Central Manufacturing Technology Institute

Return on Investment (ROI)

One of the primary challenges in the Indian market in adopting advanced CNC machines is significant investment and skilled manpower, often necessitating substantial upfront capital. These costs can be prohibitive, specifically for small and medium-sized enterprises.

The Indian market heavily relies on imported machine tools. A stronger push towards the ‘Make in India’ movement will generate great opportunities for domestic machine tool companies, which can provide better machines with robust build quality and better accuracy.

Accessing funds through various avenues like government subsidies and bank loans is simpler than ever. Individuals and businesses should proactively seek information about relevant funding schemes by central and state governments. Small and medium-sized enterprises (SMEs) can benefit from numerous tax advantages. Bank loans provide another readily available means of securing capital.

Achieving a better ROI is closely linked to a machine’s operational costs, which are directly influenced by factors such as material selection, tool selection, machine maintenance, and the availability of skilled manpower.

Choosing the right material for existing machines or selecting machinery that aligns with the nature of the work and raw materials is crucial. This ensures that machines operate at their optimal efficiency. Furthermore, the selection of tools plays a vital role in optimising the machine’s cycle time and reducing costs.

Effective maintenance is crucial for consistent operation with minimal unexpected breakdowns. Implementing preventive checks and a well-structured maintenance plan can significantly reduce the likelihood of sudden failures, improving the machine’s overall health and efficiency.

The demand for skilled manpower to operate CNC machines is substantial. Frequent training for operators addresses this challenge. A culture of continuous training will empower existing personnel, enhance their confidence, and motivate them to perform at a higher level.

AI-driven predictive maintenance for CNC machines

Predictive maintenance means identifying failure before it occurs. AI-driven predictive maintenance combines the component life cycle and real-time machine monitoring. It delivers detailed predictive analyses about components’ estimated lifespans by closely tracking specific components. AI algorithms analyse sensor data streams, historical performance records, and real-time contextual information to forecast equipment degradation and potential failures.

By spotting early indicators of trouble, AI empowers maintenance teams to proactively schedule necessary repairs or replacements, significantly minimising unexpected downtime. AI-driven predictive maintenance offers the flexibility to dynamically adjust production schedules, reallocating tasks to alternative machines if a failure is anticipated, thus ensuring continuous operations. Ultimately, this approach can extend the operational life of equipment and lessen wear and tear.

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Prakash G – Director, Turning Centre Division of Ace Designers Limited.

Leading with an example

MSMEs are thus central to inclusive industrial growth in India. Ace Designers began as a small-scale CNC machine manufacturer, founded by visionaries Mr. Shirgurkar and Mr. Machado. Forty years ago, when local CNC production seemed improbable, they defied conventional norms and introduced cost-effective solutions. Their journey focuses on cultivating a strong vision and passion, staying customer-focused, identifying and addressing meaningful market gaps, and challenging the status quo with conviction are key.

Sustainable growth for MSMEs hinges on quality, cost competitiveness, financial discipline, and adherence to global standards. If a small-scale enterprise can navigate the initial few years with resilience and strategic focus, it can thrive and scale.

India’s growing demand for precision engineering can boost domestic production of high-precision CNC machines. We currently manufacture around 5,500+ CNC turning centres and 3,000+ machining centres annually, contributing to nearly a third of India’s machine tool output.

Achieving precision manufacturing requires access to advanced mother machines for component accuracy. We invest in high-end machinery, infrastructure modernisation, and talent development to meet global quality standards.

Beyond physical infrastructure, domain expertise is key. Application engineering, particularly mechatronics-based approaches, is gaining relevance. Indian institutions are increasingly offering programs in these disciplines. Our ‘Application Lab’ initiative complements this by nurturing skilled engineers and enabling practical problem-solving that is aligned with precision manufacturing needs.

Our strategic focus includes continuous workforce upskilling, adoption of global quality standards, and end-to-end design-to-manufacture alignment, all of which are geared toward building an Indigenous high-precision CNC ecosystem.

Ace Designers exports to over 20 countries and maintains offices in China, Europe, and Mexico. It has sold more than 2,000 machines in China alone.

Our strength lies in combining affordability with quality. We’ve established a dedicated Corporate Technology Group for focused R&D and technological advancement.

Innovation is a key priority. Through our in-house ‘Application Lab’, we conduct real-world testing to refine machine performance. We’re also actively ‘Indianising’ key technologies to make them locally relevant and cost-effective. Our investment in ‘Digital Twin’ capabilities allows us to simulate machine behaviour virtually, reducing the need for physical trials and accelerating time to market.

We collaborate with institutions like CMTI and IITs to co-develop cutting-edge, sustainable solutions. Our roadmap focuses on reducing the carbon footprint and optimising total cost of ownership (TCO).

Additionally, we are deeply engaged with IMTMA and other industry bodies, participating in policy and technology development forums. We are enhancing our supplier ecosystem to uplift component quality, ensuring our solutions remain competitive and globally benchmarked.

With these initiatives, we are confident that Indian CNC technology will compete globally within the next 2–3 years.

The country is working towards its ambitious renewable energy target of 500 GW by 2030, including a mandate that at least 10% of this capacity must be backed by energy storage. With manufacturing taking the lion’s share of energy consumption, adopting new technologies that responsibly store and manage energy is imperative.

A vinyl pressing plant has reported producing about 14,000 records daily, utilising seven pressing machines that operate around the clock. Some large-scale producers can manufacture between 40,000 and 50,000 records each day. Michelin has reached impressive production levels of 100,000 tyres daily across its global plants, covering various sizes for consumer, commercial, and industrial vehicles.

Picture large production facilities tirelessly churning out products daily; such high production numbers would not be possible without the heavy, energy-consuming machinery in operation. The waste generated from production is directed toward recycling, which also relies on machinery, and ultimately, all operations hinge on a consistent energy supply. A day without energy at these facilities would result in significant losses for manufacturers. Therefore, storing and utilising energy effectively is crucial, necessitating new technology-integrated systems that prioritise energy conservation.

Energy storage and power management are part of a larger shift toward sustainable and resilient manufacturing. K G Deenathayalan, Director and CBO of Fuji Electric India, considers energy a strategic asset. Managing it well means reducing costs and improving productivity, stability, and compliance with environmental goals.

Fuji manufactures high-quality, reliable power modules tailored for various applications. These systems achieve a high power factor and low total harmonic distortion (THD), enhancing energy efficiency and reducing waste.

Deenathayalan shares that they operate in sectors where the cost of downtime or power quality issues can be very high, such as data centres, pharmaceuticals, automotive, and critical infrastructure. Due to this, they have made investments to scale up their 325,000 sq ft manufacturing space in Pune with fully automated lines to ensure operational efficiency, cost savings, and sustainability.

Manufacturing of the Energy Storage Solutions

The recent tariff policies announced by the Trump administration, mainly targeting Chinese imports into the US, can impact India’s growing battery and energy storage sector two-fold. According to a report, Subhash Sethi, Chairman of SPML Infra Limited, says the lithium-ferro-phosphate (LFP) market can be impacted since China produced 99% of LFP cells in 2024. There are also anti-dumping measures affecting the prices of anodes and energy storage systems.

Fluctuating global prices of key raw materials such as lithium and cobalt could increase production expenses. The disruptions may delay the ongoing downward trend in battery costs and limit short-term access to the latest innovations.

On the positive side, the tariffs could encourage global battery manufacturers to relocate their production to India, which has a strong domestic demand and favourable policies like the ease-of-business and production-linked incentive (PLI) scheme. This shift may open doors for more technology collaborations and quicker access to advanced battery innovations. Indian producers could also benefit from new export prospects to the US, as American buyers will seek reliable alternatives to Chinese suppliers.

Integration Challenges

Integrating renewable sources into traditional manufacturing setups involves more than just installing solar panels or wind turbines. The challenge lies in matching variable energy generation with the consistent or variations of power demands for manufacturing operations.

Many manufacturers are now adopting hybrid energy systems that combine solar, BESS, and diesel backup; all coordinated through an intelligent EMS.

Deenathayalan shares an example of a recent project with a textile manufacturer. BESS helped them align loom operations with solar generation during daylight hours while drawing from storage in the evening. This reduced their grid dependency by over 40 percent.  Manufacturers are exploring microgrids that combine storage with solar and other distributed energy sources in some industrial zones where grid reliability is limited.

Latest developments for energy storage

The pace of innovation in energy storage is encouraging, especially as more industries commit to renewable energy targets. Lithium-ion batteries dominate due to their high energy density and falling costs. Alternatives like sodium-ion and flow batteries are drawing attention for long-duration storage and specific use cases.

Options like the Sunbird off-grid/hybrid, bidirectional solar inverter, and bidirectional inverter are also available. This solution is built specifically for solar-heavy industrial setups. It is designed to handle variable solar input while managing charging and discharging cycles. It is well-suited for applications with low grid reliability or where users want to reduce diesel generator dependency.

BESS units are increasingly being deployed in hybrid and microgrid systems. These systems can store energy while improving power quality. With built-in functions for reactive power compensation, voltage stabilisation, and harmonics filtering, they are particularly effective in protecting sensitive manufacturing equipment.

Solid-state batteries are emerging as safer, higher-capacity alternatives for next-generation applications. Flow batteries, such as vanadium redox systems, offer long-duration storage with high safety and lifespan for large-scale operations. Meanwhile, sodium-ion batteries provide a cost-effective option for stationary energy storage in budget-conscious industries. Hydrogen energy storage is gaining traction, especially in decarbonisation efforts for long-term and high-capacity needs. Thermal energy storage (TES) enables efficient heat management in food processing and textiles, while compressed air energy storage (CAES) is suited for bulk storage. Second-life EV batteries also present a sustainable, low-cost option for non-critical manufacturing loads.

To complement these storage solutions, manufacturers are adopting smart energy management technologies. AI-based Energy Management Systems (EMS) provide real-time analytics and predictive insights for load optimisation and maintenance. Digital twins simulate plant energy profiles to test efficiency strategies, while IoT-based sensors detect real-time inefficiencies across machines and processes. Demand response systems help manage peak loads by adjusting consumption based on utility signals, often yielding financial incentives. Blockchain technology allows for secure, traceable energy transactions within industrial ecosystems. Microgrids and localised on-site networks integrate various energy sources to boost resilience, autonomy, and cost-efficiency, making them valuable assets for future-ready manufacturing.

Alexey Polyakov, General Manager of Air To MC2, also recommends the Maisotsenko Cycle (M-Cycle), which introduces five key thermodynamic innovations—Wet Combustion, Inlet Cooling, Phase Change of Working Substance, Waste Heat Recovery, and High Enthalpy at Low Temperature—making it one of the most efficient and affordable ways to convert heat into mechanical or electrical energy.  Wet Combustion significantly reduces NOx emissions by 10x and CO effluents by 2X while doubling thermal efficiency in manufacturing. Inlet Cooling helps increase gas turbine output by up to 25% in hot weather by cooling intake air below the wet bulb temperature. Waste Heat Recovery through the M-Cycle uses enhanced humidification to maximise energy reuse and improve overall system efficiency. The M-Power Cycle builds on these principles to deliver high thermal efficiency using renewable air energy, with minimal design changes to existing power systems. This makes the M-Cycle an innovative and sustainable energy management solution for manufacturers focused on reducing emissions and improving energy use.

Policies and government initiatives

Government policies are making energy storage more viable for the Indian industry. The Production Linked Incentive (PLI) scheme for Advanced Chemistry Cells encourages local battery manufacturing, and the government is passing on solar panel manufacturing, which helps reduce import dependence and brings down system costs over time. This supports the reduction of BESS costs for the customers.

The National Energy Storage Mission (NESM) and the draft National Energy Storage Framework provide a much-needed roadmap for industry and utilities to deploy storage systems. Viability Gap Funding (VGF) addresses cost concerns and makes investing in large-scale battery energy storage projects easier for businesses.

The Energy Storage Obligation (ESO) requires utilities to procure a share of their power from renewables supported by storage, which improves the overall ecosystem. Interest is also building through pilot projects from SECI and NTPC, and policies related to green hydrogen and solar-wind hybrid models are further reinforcing the role of storage.

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“As manufacturing evolves toward smarter and greener operations, energy storage and management have become foundational to future-proof industrial growth against energy volatility and sustainability mandates.”

K G Deenathayalan, Director and CBO, Fuji Electric India

“The Maisotsenko Cycle can greatly help industrial energy production by offering a pathway to ultra-efficient, low-emission power generation by turning waste heat into a strategic asset and scaling sustainable manufacturing.”

Alexey Polyakov, General Manager of Air To MC2

“India is committed to all 17 SDGs, particularly SDG-7 , for affordable, sustainable energy. It has electrified all villages, expanded renewable energy, and promoted clean energy policies. Additionally, under SDG-6, India aims to provide clean drinking water for all by 2030, showcasing its dedication to sustainable development and leadership in the clean energy transition.”

Subhash Sethi, Chairman of SPML Infra Limited 

EMO Hannover 2025 will present a range of inspiring innovations and solutions for engineering companies under the banner of “Innovate Manufacturing”. The event will also provide opportunities for companies to find suitable partners to support their modernisation processes.

From ice cream machines to wheel loaders, the spectrum of engineering products is as broad as the market itself. However, nearly all producers are facing the same major challenges: modernising production, developing strategies to combat the shortage of skilled workers, and implementing solutions for a more circular economy and improved resource efficiency. Under the banner of “Innovate Manufacturing”, EMO Hannover 2025, the world’s leading trade fair for production technology, will be offering engineering companies a wide range of inspiring innovations and solutions. Furthermore, companies will also be able to find suitable partners at the EMO who can provide expert support for their modernisation processes. This saves time and minimises investment risks.

Embracing new technologies

It is now crucial for the sector as a whole – and not just small and medium-sized enterprises – to embrace new technologies and solutions. Ideally, these should be scalable, have already proven their effectiveness, and raise efficiency levels right from the outset. EMO offers direct access to the leading manufacturers and suppliers of customised production solutions in engineering and showcases advances in metalworking. Visitors can experience machine tools in action at the fair. They can discuss and confer with industry experts and specialists on the trade fair stands as well as in presentations, workshops and live demonstrations.

Dr Markus Heering, Executive Director of EMO organiser VDW (German Machine Tool Builders’ Association), said, “The EMO is unique among the trade fairs in presenting the entire metalworking value chain – from machine tools, production systems and additive processes through to precision tools, automation, metrology, quality assurance, software and accessories. The EMO motto “Innovate Manufacturing” is therefore more than just a slogan; it is a call to suppliers and users to be bold in exploiting the possibilities opened up by the new technologies.”

Digitalisation is revolutionising engineering

This applies in particular to the megatrends of automation, digitalisation and artificial intelligence. Advancing digitalisation is revolutionising engineering, the VDW believes. A decisive factor here is the networking of all machines in the process chain. The opportunity to experience this live is what makes EMO unique. Machine tools now come pre-equipped with extensive sensor and monitoring systems. Exhibitors need to dispel trade visitors’ concerns about the possible loss of data sovereignty or the threat of cyberattacks. The exhibiting companies believe it is important to facilitate the transition to data-driven production. Systems that run exclusively on or in individual machines and within the customer’s own network will be on display. It is entirely up to users to decide whether they allow the exchange of data – for example, with external parties, such as the machine manufacturer or partners in or outside the value chain, either now or at some point in the future. Genuine added value is created when maintenance cycles can be predicted, downtimes can be minimised, or data for documenting the carbon footprint within the supply chain can be issued at the touch of a button.

Machine learning, a sub-area of artificial intelligence, opens up a new dimension of self-organising production. This allows companies to respond more flexibly to changes in the market and to individual customer demands. It is a crucial prerequisite for maintaining innovativeness and competitiveness in the long term.

Addressing skilled labor shortages

Digitalisation and automation of production can be combined with strategies aimed at countering the shortage of skilled workers in engineering. Automated assistance systems, for instance, can support machine operators while simultaneously increasing productivity, quality and efficiency. In addition to technical solutions, EMO is also addressing the question of how the training programs for the next generation of skilled workers can best be adapted to meet the latest requirements regarding technological development, digitalisation and artificial intelligence.

The changes affecting engineering also include sustainability. More and more countries are taking measures to protect the climate and invest in the green transformation of their industry. In production, there is a stronger focus on consuming resources more sparingly, using energy-efficient machines and production processes, and setting up circular economies for products and materials. As the VDW reports, immensely high visitor interest in this topic was already apparent at EMO 2023. The Sustainability Area at EMO 2025 will provide a focal point for modern solutions aimed at bringing about the sustainable production of the future and at answering visitors’ questions. This is a topic which is clearly at the top of the agenda when it comes to the modernisation of production.

Swan Defence and Heavy Industries Limited (SDHI) has signed a strategic Memorandum of Understanding (MoU) with Wheel & Time Shipping Transport Logistics to launch India’s first integrated F.A.S.T. (Fabrication, Assembly, Storage, and Transportation) commercial logistics ecosystem at its state-of-the-art shipyard in Pipavav, Gujarat.

Swan Defence and Heavy Industries Limited (SDHI), India’s largest shipbuilding and heavy fabrication company, has signed a strategic Memorandum of Understanding (MoU) with Wheel & Time Shipping Transport Logistics, a specialist in moving heavy and oversized cargo. With the alliance, SDHI has launched India’s first integrated F.A.S.T. (Fabrication, Assembly, Storage, and Transportation) commercial logistics ecosystem at its state-of-the-art shipyard in Pipavav, Gujarat.

The F.A.S.T. model offers an unmatched turnkey ecosystem for executing heavy engineering projects in India by bringing together SDHI’s advanced fabrication and waterfront infrastructure and Wheel & Time’s end-to-end heavy logistics capabilities. The partnership will benefit high-value, time-sensitive projects and will target clientele dealing with material handling equipment at ports, marine infrastructure, petrochemicals, offshore EPC, oil & gas infrastructure and heavy engineering.

This one-of-a-kind model is designed to help companies to shorten project execution timelines, minimise handoffs, reduce overall project risks, and offer scalable solutions connected to global shipping networks.

Vivek Merchant, Director, Swan Defence & Heavy Industries Limited (SDHI), said, “New builds, ship repairs, and heavy fabrication are central to SDHI’s growth plans. With strong capabilities in shipbuilding and repairs, this partnership with Wheel & Time Shipping Transport Logistics enhances our heavy engineering operations. Together, we can offer customers a more integrated, end-to-end solution. The F.A.S.T. logistics ecosystem allows EPC contractors and heavy industry players to concentrate on innovation and last-mile delivery, while we manage the complexities from fabrication to transportation.”

Gautamraj Sharma, Managing Director, Wheel & Time Shipping Transport Logistics, said, “We are elated to partner with SDHI. We believe our collaboration with them brings together the best of deep fabrication infrastructure and robust logistics know-how. The F.A.S.T. logistics ecosystem will enable clients to de-risk projects and improve certainty across timelines, execution, and delivery.”

Spread over 600 acres with 1.2 kilometres of developed waterfront, SDHI has India’s largest dry dock with a capacity to fabricate and assemble structures of 10,000 tonnes per month. The shipyard has advanced CNC (Computer Numerical Control) and robotic systems for cutting steel. It also has powerful hydraulic presses that can handle up to 1,600 tonnes for precise manufacturing. The facility also provides the capabilities to make large sections and offers specialized equipment for lifting of heavy items.

From importing material to final shipment, every phase of the value chain is handled on-site, eliminating the need for inland transport and multiple vendor coordination. Through this alliance, Wheel & Time will arrange an extensive fleet of heavy-lift equipment, including Self-Propelled Modular Transporters (SPMTs), hydraulic trailers, and marine transport vessels, enabling the seamless movement of over-dimensional/oversized cargo to worldwide locations.

Jindal India Limited, has invested Rs 100 crore in the steel section pipes and tubes segment. The company aims to achieve a monthly production capacity of 5000 metric tonnes. The move aims to penetrate current markets and strengthen its foothold in new regions.

Jindal (India) Limited, part of the prestigious B.C. Jindal Group and one of the leading downstream steel products manufacturers in India, has announced its foray into the steel section pipes and tubes segment with an investment of Rs 100 crore at its state-of-the-art manufacturing facility in West Bengal.

A leading national player, Jindal (India) Limited aims to achieve a monthly section pipes and tubes production capacity of 5000 metric tonnes (MT), which is expected to translate into a sales revenue of Rs 315 crore in FY26. With this move, the company plans to further penetrate the current markets while simultaneously strengthening its foothold in new regions across the country.

The company, with this foray, aims to supply the product to an array of sectors which will include infrastructure, agriculture, railway, warehousing, and residential housing, to name a few.

Jindal (India) Limited is one of the oldest players in the downstream steel product industry. Historically, a significant portion of the company’s revenue has been driven by the eastern region, followed by South India. However, over the years, the company has adopted a pan-India strategy, expanding into North and West India through increased capacity growth. Currently, contributions from these two regions make up approximately 15% of its revenue, and the company aims to increase this to 30% in the near future. Jindal (India) Limited sees immense potential in these regions due to the rapid growth in infrastructure development and industrial projects. The company is committed to solidifying its foothold in existing markets while expanding into these key regions vital for growth.

Jindal (India) Limited has two state-of-the-art factories located at Howrah, West Bengal, and its capabilities include advanced colour coating, galvanising, and galvalume technologies. The company offers a comprehensive range of products across three major divisions that include sheets, pipes, and aluminium foil. With strong brands like Jindal Sabrang and Jindal NeuColour+, Jindal (India) Limited dominates the colour-coated sheets market, particularly in Eastern India, and maintains a significant presence across the country. Currently, 70% of the company’s total production consists of coated flat steel products, which remains a key area of focus for future growth and expansion.

Automation Studio Code is an advanced development add-on for Automation Studio 6, offering a modern, intuitive interface and advanced engineering features. It integrates with Automation Studio 6, allowing for seamless integration and flexibility.

Automation Studio Code offers engineering teams a whole new way to interact with their projects and each other. A modern, intuitive interface and advanced engineering features make work easier than ever. DevOps integration ensures smooth, efficient and reliable software delivery pipelines. Explore the new world of engineering with the advanced development add-on for Automation Studio Code.

This development plug-in is perfectly integrated into Automation Studio 6 and makes working on a project with two tools possible without any migration required , fully compatible and flexible. Efficient automation starts with an AI-powered expert coding assistant, and with the flexibility of cloud-based collaboration, developers can do their best work and deliver smarter solutions faster.

UiPath’s AgentHack 2025 sets the stage for global innovators to design next-gen AI agents. The hackathon reflects UiPath’s push to lead the future of intelligent, agent-driven automation.

UiPath, a global pioneer in enterprise automation and AI technologies, has announced the start of Global AgentHack 2025, a virtual hackathon to advance agentic automation. Introduced at UiPath DevCon 2025, the global competition challenges contestants to create novel AI agents utilising UiPath’s tools and platform.

This one-of-a-kind hackathon is solely focused on agentic automation. Participants will create AI agents in different categories, such as Agent Builder, Agentic Orchestration, Agentic Testing, and Role-based Agentic Agents. The programme prioritises practical, hands-on development over theoretical ideas, emphasising real-world use cases and enterprise applications.

The hackathon is open to developers, data scientists, AI specialists, students, and industry experts. Individuals or teams of up to four can compete. Submissions should illustrate AI agents’ potential to drive corporate transformation.

Sebastian Schroetel, Senior Vice President of Product Management at UiPath, said, “AgentHack is a platform for global innovators to explore agentic automation using UiPath tools.” We look forward to receiving groundbreaking ideas that will use AI agents to reinvent business effectiveness.

UiPath will provide participants with access to workshops, mentorship sessions, and enablement programmes throughout the competition. Finalists will be given the opportunity to incorporate their projects into the UiPath ecosystem and display them on the UiPath Community Forum.

Bobby Patrick, Chief Marketing Officer at UiPath, said, “AgentHack 2025 reflects our commitment to empowering the developer community. With the reimagined UiPath Platform™ for agentic automation, this hackathon marks a major milestone in our journey to scale AI-driven automation.”

Key Dates:

• Registration Deadline: July 7

• Finalists Announcement: July 25

• Final Event: August 5

• Winners Announcement: Mid-August

The entire prize pool for AgentHack 2025 is $50,000, with individual category winners receiving cash awards of up to $5,000. Winners will also receive UiPath certification vouchers and other advantages to help them advance their professional development and visibility in the field of agentic automation.