Advancements in warfare technology have made weapons, artillery, and explosives more lethal. Rising insurgencies and asymmetric conflicts worldwide demand a significant shift in security and defence strategies. A crucial part of the modern-day security and defence ambit is vehicle armour. This includes specially designed and engineered protection for military, paramilitary, police, and special civilian defence vehicles, protecting personnel and machinery from incoming threats against high-velocity projectiles.
Metals like alloy steels, titanium, etc., were used for armour protection. However, as threat levels evolved, these were limited in offering sufficient protection and vehicle mobility. Although these metals offer limited performance, their weight makes the vehicles heavy and fuel-inefficient. The vehicle also lacked certain properties that could help mitigate the impact of oncoming ballistic threats or blasts.
Armour protection needs the right degree of hardness and strength to mitigate the threat of high-velocity projectiles while deflecting their kinetic energy across a large area and absorbing the shock of the impact. This demanded the search for high-performance, lightweight solutions.
Manufacturers and engineers then used polymer-based soft armour panels to counter low-level threats. However, while polymers are lightweight, they fall short of offering adequate protection against high-level threats. This is where ceramics and hybrid composites have proved to be the most impactful.
Ceramics and composites, in conjunction with metallic back-plates, are cost-effective alternatives to metal alloys in terms of performance cost. This is because the ceramic composite armour panel has a low density, making it nearly one-third the weight of its metallic counterparts while offering a cost-effective, high-performance protection solution. Their superior hardness and ability to shatter incoming projectiles significantly enhance protection, improving the performance-to-weight ratio by more than three times. This makes the vehicle more resilient, lighter, fuel-efficient, better performing, and protected.
Ceramic composites, typically reaction-bonded silicon carbide (RBSiC), Zirconia Toughened Alumina (ZTA), or Alumina backed up with high-performance polymers, are popular for armour vehicles. They are mounted onto a special mother plate by employing a suitable mechanism.
Ceramics like RBSiC are hard, strong, cost-effective, and absorb kinetic energy against a high-velocity projectile. This property means that the kinetic energy of the incoming threat will be quickly absorbed within an optimum designed area of the ceramic armour along with backup polymeric materials, thus significantly reducing its extent of attack. In India, ceramic composites have recently emerged as the material of choice for vehicle armour.
Light Battle Tanks maintain a high power-to-weight ratio. This is particularly critical to traversing mountainous terrain in remote and inaccessible areas and operating in extremely high altitudes. Their superior performance at ideal weight enables them to perform well in such conditions.
Main Battle Tanks are neither built for easy manoeuvrability, especially in such regions, nor are they equipped to navigate such challenging conditions. Tanks are facing several performance issues due to rarefied air, for example. Moreover, airlifting battle tanks to deployment areas remains one of the primary challenges.
In this scenario, weight reduction resulting in a much lighter tank is critical to address these issues.
A definite route to achieving such significant weight reduction is to replace steel with parts engineered using advanced technical ceramics with low density and high hardness. This ensures robust armouring capability against projectiles and faster and more agile deployment of battle tanks. It also improves fuel efficiency and tactical manoeuvrability.
The Wheeled Armoured Platform (WhAP) is designed to focus on modularity, scalability, and reconfigurability, allowing it to be adapted for a wide range of roles and operational needs. Armour designed using advanced technical ceramics will enable the highest ballistic protection without overshooting these weight restrictions. In September 2024, CUMI was awarded the Transfer of Technology by DRDO-DMRL to manufacture add-on composite armour for WhAP and other armoured vehicles.
The indigenously manufactured elastomeric add-on composite armour panels are designed using customised ceramic segments sandwiched between rubber and backed up by a metallic mother plate that is impact, UV, and weather-resistant. Engineered to contour the vehicle precisely, they enable superior mobility with the highest safety and ballistic protection.
Vehicles are designed per the desired protection level, which depends on the specific defence application the vehicle needs to fulfil. While some are designed to offer only ballistic protection, others can withstand blasts and shrapnel.
Armoured vehicles can be categorised under specific protection levels based on the specified ballistic threat level protection requirements. For ballistic testing, a predetermined number of kinetic energy threat rounds are fired at the target (armoured parts). The absence of complete perforation and back-face signature indicates that the desired level of protection has been achieved and is governed by the STANAG 4569 standard.
Armoured vehicles are designed to offer protection at three levels to mitigate both blast impact and shrapnel damage:
This mitigates blast impact and shrapnel damage. Specific vehicle types, such as those used to ferry VVIPs, such as Presidents, Prime Ministers, Ministers and Heads of state, are suitably adapted to offer the required protection level. In addition, vehicles must be weather-resistant and UV-resistant, endure extreme temperatures, function on a specific terrain or adapt to multiple terrains (e.g., amphibious vehicles) based on specific needs.
Diamonds are the hardest naturally occurring mineral, with a rating of 10 on the Mohs hardness scale. Although synthetically produced, silicon carbide (SiC) comes very close at a rating of 9 next to diamond.
To take further advantage of an expansive set of properties not limited to high hardness and excellent wear resistance, high strength, and low density, it is manufactured through different processes as per the demand of the application required. Its extraordinary hardness, low density, lighter weight, and very high specific strength and cost efficiency have rendered protective ceramics such as RBSiC invaluable in defence and aerospace applications. Since it can be customised to many shapes and sizes, it has high wear resistance and ensures dimensional stability.
RBSIC is commonly used in an extensive range of geometries. It can also be used to design customised polygonal plates that enable accurately lining larger, more complex surfaces according to their exact dimensions, making it perfect for vehicle armour applications. This also takes multiple hits and effectively disperses the destructive capability of projectiles developed to penetrate and destroy armour. All these key advantages have put RBSIC at a high level for global vehicle armour manufacturers.
CUMI’S CUMICARB_RR RBSIC products are designed to withstand harsh environments while delivering outstanding performance. Engineered to be extremely strong yet lightweight and ensure high reliability, CUMI’s RBSiC innovations for vehicle armour, such as rubberised ceramics, enable efficient protection of soldiers and machinery in the vehicle. CUMI is significantly increasing its RBSiC armour product manufacturing capacity to meet the needs of indigenous armoured fighting vehicles.
The vehicle armour protection needed will depend on the requirements of the defence application that it is meant to serve. Different armoured vehicles come with a prerequisite for varying degrees of protection levels.
The key factors that determine the scope of a defence application are:
Here’s a look at the five protection levels mentioned in STANAG 4569:
Emerging trends and innovations: Exploring ceramic’s role in future vehicle protection
The role of ceramics is being explored in the design of blast-resistant hulls and vehicle chassis. While earlier, these parts were made of steel, new designs, such as the ‘V-shaped monocoque hull’, have made it possible to use composite materials. In some recently produced composite hull designs, several advanced composites have been used to equip vehicles with lightweight protection and ensure better performance. Research indicates that the composite V-shaped hull offers enhanced protection against IED blasts.
CUMI is one of India’s few manufacturers of technical and high-quality ceramic products for defence applications. It manufactures RBSIC, high-purity Alumina, and ZTA, which offer better mechanical performance with reduced weight. CUMI also co-creates customised solutions, including advanced ceramic component offerings, for various OEMs and automotive companies for their products and processes.
Ceramics and composites will emerge as a preferred option for vehicle protection. They will continue to become even more high-performance, efficient, lightweight, resilient, and hard-to-wear materials. Innovations will continue to improve the efficiency of the backup material in composites, be it the p-Aramid fibre, ultra-high molecular weight polyethene (UHMWPE), and high-performance resin and elastomeric materials.
The design of the ceramics and composites panel, mounted on the mother plate of the vehicles and its materials, would become better, more high-performance materials. The key engineering considerations revolve around improved performance, weight reduction, and vehicle protection costs. Thus, ceramic composites will, in future, be the backbone of resilient, high-performing, lightweight defence and special civilian vehicle protection.
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Hannover Messe 2025, held in the historic city of Hannover, Germany, has once again set the stage for showcasing the latest advancements in industrial technology. Spanning across 5 days, from March 31 to April 04, this year’s theme focused on “Shaping the Future with Technology”, reflecting the urgent trends towards sustainability, carbon neutrality, digital transformation and technological integration in the industrial world.
The Hannover Messe 2025, the biggest event in the smart manufacturing world, attracted 4,000 exhibitors from 65 countries and welcomed 127,000 visitors to the German city of Hannover last week. According to the organisers, these figures are similar to last year’s, although they remain significantly lower than pre-pandemic levels. While this might represent a new normal for trade shows, many serious commercial prospects still appreciate the chance to see live demonstrations and take advantage of extensive networking opportunities.
As the partner country for 2025, Canada was notably represented with 250 exhibitors showcasing its expertise in artificial intelligence, quantum technology, electric vehicles, and clean energy.
Hannover Messe 2025 showcased several key highlights that emphasised the evolving landscape of industry and technology. There was a strong emphasis on artificial intelligence (AI) and Industry 4.0, highlighting the integration of advanced technologies into manufacturing processes. Additionally, the event spotlighted innovative solutions related to green hydrogen and clean energy, underscoring the importance of sustainability in industrial practices. The focus on digital platforms and smart manufacturing illustrated the growing trend of automation and connectivity in production processes. Lastly, Hannover Messe 2025 provided a dedicated platform for startups, fostering innovation and entrepreneurship in the industry.
Dr Gunther Kegel, President of the ZVEI quoted “HANNOVER MESSE has once again shown that it is the most important platform for industrial innovation. AI in industrial applications was of particular interest to visitors, especially those from abroad. This shows that German industry can continue to offer a global orientation in times of technological change. Our companies are leaders in Industrie 4.0, and we are convinced we can further expand this starting position. Industrial AI is a new growth area that will continue to drive the automation and digitalisation of industry. HANNOVER MESSE will reflect this development in the coming years.”
Thilo Brodtmann, Managing Director of the VDMA, mentioned, “This year’s HANNOVER MESSE has shown how important good partnerships and open markets are for an export and innovation-driven industry such as machine building and plant engineering. The willingness of host country Canada to deepen trade with Europe is welcome and encouraging news in a world increasingly characterised by trade disputes. To master the major tasks ahead of us, we need innovations such as those impressively demonstrated in all halls at the event. This year, HANNOVER MESSE also sent a strong economic policy signal to Berlin: The industrial sector urgently needs a location upgrade to continue demonstrating its innovative strength here in the country.”
This year, Indian participation at Hannover Messe was coordinated and widely visible. The India Pavilion was a significant hub for business inquiries, technical demonstrations, and policy discussions. Supported by the Engineering Export Promotion Council of India (EEPC) and the Government of India, Indian exhibitors aimed to position the country as a global manufacturing partner and technology collaborator, rather than merely a cost-efficient destination.
According to sources from the EEPC, approximately 61 companies participated in the event. Of these, 21 companies were backed by the EEPC, while 40 operated independently.
Indian companies showcased their capabilities in the following areas:
– Advanced Manufacturing and Automation
– Precision Engineering
– Digital Twins and IIoT
– Manufacturing-as-a-Service (MaaS)
– Electrical Equipment
– Factories of the Future
– Green and Clean Energy
– Aerospace and Defense
– Automobiles and more.
While speaking with OEM Update magazine, Arun Ramu, CEO of MachineMaze, shares, “Platforms like HANNOVER MESSE truly enable companies to connect with global customers where the actual markets are. In India, while the country has made significant strides in manufacturing, we are still in the process of catching up in developing high intellectual property (IP) value products. This makes HANNOVER MESSE an ideal platform for customer outreach, exploring engineering complexity, discovering core technology solutions, and showcasing the value we can bring to customers globally.”
Smit Patel, International Sales, Deep Sheet Metal Components Pvt. Ltd. , highlighted that European markets place a higher premium on quality, precision, and process integrity over price competitiveness. To succeed in this environment, it’s crucial to uphold exceptional standards in our products, operations and how we treat our workforce. Long-term success in Europe hinges on building a reputation rooted in reliability, consistency, and ethical business practices. These values are not just appreciated—they’re expected.
Rajesh Nath, Managing Director, VDMA India underlined that German companies already present in India are now sourcing from India to further strengthen their partnership. This provides a great opportunity for Indian companies to explore European markets.
Hannover Messe remains a hub of technology, setting benchmarks that enable industries to adopt innovations to make LIFE SIMPLE and the PLANET GREENER.
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NKP Pharma partnered with Rockwell Automation to overcome regulatory and data access challenges by implementing FactoryTalk® Optix™, a modern HMI solution. This case study shows how the transformation enabled cost-effective 21 CFR Part 11 compliance and enhanced customer satisfaction through improved data accessibility and performance.
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NKP Pharma, a pharmaceutical machinery manufacturer, is committed to innovation and delivering advanced solutions that meet the evolving demands of the pharmaceutical industry. Established in 1988, NKP launched its first automatic machine for sterile dry powder injectable filling. Today, NKP Pharma is a significant player in India’s pharmaceutical packaging machinery sector.
Challenges faced by NKP Pharma:
NKP faced a significant challenge navigating the pharmaceutical industry’s stringent regulations, particularly compliance with USFDA 21 CFR Part 11. These regulations govern electronic records and signatures, protecting data integrity and traceability in pharmaceutical manufacturing.
Traditional IPC-SCADA systems, designed to achieve 21 CFR Part 11 compliance, had become cost-prohibitive. For NKP Pharma, implementing the IPC-SCADA solution across all their machines strained budgets and passed on high costs to customers. Additionally, the current setup centralised data management with NKP Pharma, leaving customers without direct access to their operational data. This lack of accessibility created a hurdle for customer satisfaction and operational efficiency.
Solutions offered by Rockwell Automation:
NKP sought a cost-effective solution that supported compliance with 21 CFT Part 11 while granting customers access to more of their data. Turning to Rockwell Automation, NKP Pharma looked to modernise its systems without compromising quality or compliance.
Rockwell Automation recommended FactoryTalk® Optix™, a next-generation HMI solution for advanced visualisation and seamless data integration. FactoryTalk® Optix™ simplifies automation and enables real-time insights into machine operations. Its flexibility and user-centric design make it an ideal choice for pharmaceutical manufacturing environments requiring regulatory compliance and robust data management.
NKP Pharma initiated a pilot project to test the solution on their inspection machine. As part of the implementation, the company included 21 CFR Part 11 criteria, such as user-level access control, alarm reporting, and online reporting. This structured experiment with FactoryTalk® Optix™ allowed NKP Pharma to reap the benefits of modernising their system before deploying it onto other machines on their floor and customer machines.
Results achieved:
The pilot project FactoryTalk® Optix™ delivered impressive results. The new HMI solution met compliance requirements while reducing expenses.
“I can proudly say that after implementing FactoryTalk® Optix™ during our pilot phase, we have the cost-effective solution for the market concerning the costly solution of IPC-SCADA,” said Alpesh Mistry, Vice President of Operations, NKP Pharma.
Following the pilot project’s success, NKP Pharma successfully implemented the FactoryTalk® Optix™ on customer machines. Customers appreciated the improved accessibility and performance, leading to increased orders for machines equipped with the new HMI solution.
The company now plans to integrate FactoryTalk® Optix™ into their filling line machinery and diversify their portfolio with advanced injectable pharma solutions, such as blow-fill-seal machines and cartridge-filling machines.
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Honeywell has launched Honeywell Protonium, a suite of AI and machine learning technologies designed to make green hydrogen production more efficient, cost-effective, and scalable. The technology will be deployed by Aternium, a US-based large-scale producer of clean hydrogen.
Honeywell announced the launch of Honeywell Protonium™, an advanced suite of technologies enabled by artificial intelligence (AI) and powered by machine learning (ML) designed to make the production of green hydrogen more efficient, cost-effective, and scalable.
Honeywell Protonium will first be deployed by Aternium, a US-based large-scale producer of clean hydrogen, who will leverage the new technologies across its planned Mid-Atlantic Clean Hydrogen Hub (MACH2), one of seven national hydrogen hubs selected for an award by the US Department of Energy.
To help meet industries’ growing energy demands and support a broader range of sources, Honeywell Protonium helps scale green hydrogen production by tackling key challenges such as power intermittency, carbon intensity reduction, and high production costs. The new solution enhances electrolysis efficiency and optimises plant design and operations by integrating predictive control algorithms, making hydrogen production more sustainable and cost-effective.
Andrew Cottone, CEO and Founder of Aternium, said, “Our selection of the Honeywell Protonium™ portfolio for our planned Mid-Atlantic sites was a strategic decision to ensure we operate with the highest efficiency and safety standards. Honeywell’s proven expertise and innovative solutions will be instrumental in helping us achieve our mission of producing clean hydrogen with an exceptional commitment to safety while adding value for our communities and investors.”
“Honeywell is helping to accelerate the commercial viability of green hydrogen use through optimised design and improved efficiency of plants,” said Pramesh Maheshwari, President of Honeywell Process Solutions. “As adoption of green hydrogen as a diversified energy source continues to grow, it is crucial for producers to look to autonomy to ultimately advance electrification and the energy transition. With these new technologies, we are helping to further reshape the green hydrogen landscape and equip producers with the transformative solutions they need to scale.
The Honeywell Protonium™ portfolio includes three innovative offerings:
Concept Design Optimiser – optimising plant design to lower the Levelised Cost of Hydrogen (LCOH) and enable quicker investment decisions
Hydrogen Electrolyser Control System – analysing an electrolyser’s performance for greater efficiency and longevity
Hydrogen Unified Control and Optimiser – streamlining energy management and operations across the plant to reduce operating expenditure by leveraging technologies such as digital twins, AI/ML optimisation and predictive analytics
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The automotive industry is experiencing a significant transformation due to the rise of autonomous driving technology, with Light Detection and Ranging (LiDAR) technology being a critical component. The global automotive LiDAR market is set to grow an astounding 6.7 times, from USD 960.9 million in 2025 to USD 6,455.9 million in 2032.
In recent years, the automotive industry has experienced a major transformation, primarily due to the rise of autonomous driving technology. One of the most critical innovations driving this revolution is Light Detection and Ranging (LiDAR) technology. Automotive LiDAR, a key component in enabling vehicles to see and navigate their environment, is poised for tremendous growth. According to projections from Persistence Market Research, the global automotive LiDAR market is set to grow an astounding 6.7 times, from the current size of USD 960.9 million in 2025 to USD 6,455.9 million in 2032. This represents a compound annual growth rate (CAGR) of 31.3% from 2025 to 2032. In this blog post, we will delve deeper into how innovations in sensor technology are driving this growth and explore the implications for the automotive industry.
Before diving into the market dynamics, it’s important to understand what automotive LiDAR is and why it’s critical for autonomous driving. LiDAR is a remote sensing method that uses laser pulses to measure distances to objects. When these laser pulses are directed at an object or surface, they reflect back to the sensor, which calculates the distance based on the time it takes for the pulse to return. By emitting hundreds of thousands of laser pulses per second, LiDAR systems create high-resolution 3D maps of the vehicle’s surroundings, enabling real-time decision-making and enhancing a vehicle’s ability to detect obstacles, pedestrians, road signs, and other critical elements of its environment.
LiDAR technology is particularly vital for autonomous vehicles because of its superior ability to work in a variety of lighting conditions, including low light and night-time driving, where traditional cameras and radar systems may fall short. LiDAR sensors are also extremely accurate, providing the high-resolution data required for safe navigation in complex environments.
The growth of the automotive LiDAR market is closely tied to continuous advancements in sensor technology. Early LiDAR systems were large, expensive, and difficult to integrate into production vehicles. However, over the years, innovations in sensor miniaturisation, cost reduction, and performance enhancement have made LiDAR systems more viable for mass-market adoption.
Miniaturisation and cost reduction: One of the most significant breakthroughs has been the development of smaller, lighter LiDAR sensors that are easier to integrate into vehicle designs. Early LiDAR sensors, with their bulky form factors, were primarily used in research and development, with only a handful of prototype vehicles incorporating them. Today, however, companies have developed more compact, cost-effective LiDAR sensors that can be mass-produced and installed in consumer vehicles. This is primarily due to advancements in semiconductor technology and innovations in photonics.
Solid-State LiDAR: One of the most exciting advancements in LiDAR technology is the rise of solid-state LiDAR sensors. Traditional LiDAR sensors rely on moving parts, such as rotating mirrors, to scan the environment. These moving components can be prone to wear and tear, making them less reliable and durable for long-term use. Solid-state LiDAR, on the other hand, eliminates moving parts by utilising electronic beam steering or other non-mechanical methods to scan the environment. This makes solid-state LiDAR more durable, cost-efficient, and scalable for mass production. Major players in the LiDAR market, such as Velodyne, Luminar, and Innoviz, are driving innovation in this space, with solid-state LiDAR becoming a major area of focus.
Improved range and resolution: Sensor improvements have also led to LiDAR systems with enhanced range and resolution. This is crucial for autonomous vehicles, as they need to detect objects far in advance to make safe driving decisions. For instance, some of the latest LiDAR sensors can detect objects up to 300 metres away with high precision, enabling vehicles to detect pedestrians, vehicles, and other obstacles well before they come into range. These improvements in range and resolution make LiDAR an even more attractive option for autonomous vehicle applications, where high levels of accuracy and safety are paramount.
The global automotive industry is experiencing a rapid shift towards autonomous driving technology. With major companies such as Tesla, Waymo, and Cruise leading the charge, autonomous vehicles are becoming a reality rather than a futuristic concept. As these vehicles rely on a combination of sensors, including LiDAR, cameras, radar, and ultrasonic sensors, to navigate safely, the demand for advanced LiDAR technology is skyrocketing.
LiDAR plays a crucial role in ensuring that autonomous vehicles can navigate complex environments. Unlike traditional driving, autonomous vehicles need to process vast amounts of real-time data from their surroundings to make split-second decisions. LiDAR technology provides the high-resolution, three-dimensional data required to map out the environment in minute detail, helping autonomous vehicles detect road markings, pedestrians, and other vehicles with unparalleled precision.
Given the emphasis on safety in autonomous vehicle development, the demand for reliable and accurate LiDAR sensors is only expected to increase as these vehicles become more mainstream. The integration of LiDAR into fully autonomous vehicles is expected to drive the largest portion of market growth in the coming years.
Governments around the world are beginning to implement regulations that promote the development and deployment of autonomous vehicles. For example, the National Highway Traffic Safety Administration (NHTSA) in the United States has been working on regulatory frameworks for autonomous driving systems, which may soon make it mandatory for autonomous vehicles to be equipped with high-performance sensors like LiDAR.
As the regulatory landscape continues to evolve, automotive manufacturers are increasingly under pressure to integrate cutting-edge safety technologies, including LiDAR, into their vehicles to comply with these standards. Moreover, governments are also investing heavily in infrastructure that supports autonomous vehicles, such as smart traffic systems and dedicated lanes, which will further increase the reliance on advanced sensors like LiDAR.
The rapid growth of the automotive LiDAR market can also be attributed to increased investment in research and development (R&D). The automotive industry, along with technology companies, is pouring significant resources into R&D efforts to improve the performance of LiDAR systems. This investment is helping to accelerate the pace of innovation, making LiDAR sensors more affordable, efficient, and widely applicable.
In particular, collaborations between automakers, tech firms, and sensor manufacturers are leading to breakthroughs in sensor fusion, a technique that combines data from multiple sensors (including LiDAR, radar, and cameras) to create a more comprehensive understanding of the vehicle’s surroundings. These efforts are pushing the boundaries of what is possible with LiDAR technology, allowing vehicles to navigate in increasingly complex environments.
As the automotive industry moves toward fully autonomous vehicles, the role of LiDAR technology will become increasingly important. Market projections indicate that the automotive LiDAR market will experience a compound annual growth rate (CAGR) of 31.3%, growing from USD 960.9 million in 2025 to a staggering USD 6,455.9 million by 2032.
This growth will be driven by innovations in sensor technology, improved performance, cost reductions, and an increasing emphasis on safety and regulatory compliance. As LiDAR becomes more affordable and integrated into mainstream vehicles, the adoption of autonomous driving technology will be propelled forward, bringing the industry closer to realising a future where self-driving cars are the norm.
The automotive LiDAR market is on the brink of an explosive growth phase, driven by remarkable advancements in sensor technology. Miniaturisation, cost reduction, and the development of solid-state LiDAR systems are enabling mass adoption of this once-costly technology. As autonomous vehicles continue to evolve and become mainstream, LiDAR will play an integral role in ensuring the safe operation of these vehicles. With a projected growth rate of 31.3% CAGR from 2025 to 2032, the automotive LiDAR market is poised for a bright future, making it a critical component in the ongoing transformation of the automotive landscape.
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Metal foam and per- and polyfluoroalkyl substances (PFAS) substitution are being explored at EMO Hanover 2025. These innovative materials, which can float in milk, are designed to increase sustainability and improve the ecological footprint of industrial production.
This piece of metal is so light and airy that it even floats in milk. The innovative material, comprising up to 90% air, possesses remarkable properties. In the factory, it ensures greater sustainability and helps improve the ecological footprint of industrial production.
Due to increasing regulatory requirements, production technology providers all over the world are confronted with the challenge of integrating efficient and environmentally friendly materials. The solutions already available can be seen at EMO Hanover 2025, the world’s leading trade fair for production technology, which takes place from 22 to 26 September. The main focus is on metal foams and substitutes for per- and polyfluoroalkyl substances (PFAS).
Metal foams help to make machines more efficient, lighter and more stable. Similar to its natural role models, bone or wood, the highly porous material has a cellular structure, which can absorb energy in the form of oscillations, impact or sound.
Like baking bread
Aluminium foam can be manufactured in a process that, in principle, is similar to baking bread. Take some powder, a blowing agent and heat, and the finished product is aluminium foam. However, the manufacture of the high-tech material is somewhat more difficult. “For the manufacture of aluminium foams, an aluminium alloy and a blowing agent are mixed together, in most cases are pre-compacted by axial compression and then compressed into foamable sections by extrusion,” explains Carsten Lies, Head of Department Functionally Integrated Lightweight Construction at the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) in Chemnitz. “For the manufacture of aluminium foam sandwiches, customised, foamable aluminium sections are placed between two cover sheets positioned at a distance from each other,” adds the engineer, describing the production process.
In the subsequent heat treatment the foamable aluminium expands many times over. The arising foam forms a solid bond with the two cover sheets to create a sandwich. After cooling, the sandwich is cut to the final dimensions. “Metal foams, especially aluminium foams, are primarily used as core material in sandwiches,” explains Lies. Their cover sheets are usually made of steel or aluminium. “The top layers support loads; the core prevents direct contact between the sheets,” is how the Fraunhofer researcher explains the special properties of the high-tech material. The bond between top layers and core generally happens in the metallic adhesive bond.
Airy, light and rigid: sandwich with foam filling
“Depending on their design, sandwiches have very high bending stiffness. This effect is used to make assemblies lighter and thus maintain or even improve the stiffness of the assembly,” said Lies. They are replacing massive elements of the conventional assembly. According to the researcher, depending on the optimisation criterion, either significant weight savings with the same stiffness (up to around 30 per cent) or substantial increases in the stiffness with consistent weight can be achieved. The specific advantages when using metal foam in the machine in terms of efficiency and sustainability are, according to Lies, “significantly improved damping by the foam core and weight savings with the use of sandwiches”.
The fact that metal foams can also be easily recycled has a positive effect on the ecological footprint. “As no adhesive is used for the sandwich production, the material can be used in existing cycles for the treatment of metal scrap comprising steel and aluminium,” said the researcher from Chemnitz
Custom-fit from the 3D printer
Components made of metal foam – or more precisely, components made from hybrid porous (HyPo) materials – can also be manufactured in 3D printing. Advantage of additively manufactured metal foam: The air chambers can be accurately positioned. Components produced in this manner can be further optimised for special applications because the graded adjustment of the pore structure inside the component allows more options than air blowing in metal as they are formed during foaming by gas. For instance, machine components can be formed in the 3D printer with custom-fit and precisely defined properties.
“A graded adjustment of pore structure and property profiles is very difficult or not even possible in a monolithically manufactured material, as either the manufacturing process or the further processing to the final component geometry do not match the final requirements of the use,” explains Thomas Hassel from the Institute of Materials Science at the Leibniz University Hanover (LUH). The doctorate engineer highlights that additive manufacturing manages to enable near-net-shape production of components and, at the same time, introduce the grading at the corresponding places in such a way that it is positioned precisely in the profile of requirements.
The research addresses specific applications in the machine tool industry and how the innovative material can help increase efficiency and sustainability in the factory. The focus is on components of a machine tool (tool changer, tool holder, spindle carrier) with regard to their stiffness, damping, thermoelastic behaviour, and imbalance, as well as their hardness and surface quality, explains Hassel. Through the implementation of the HyPo components, e.g., in a shaper, research is carried out on what advantages are achieved with the graded components. “The operating behaviour during processing is to be analysed as the milling process involves a wide range of different loading conditions,” said Hassel. “This makes it possible to determine the influence of the HyPo component on the mechanical and thermal machine properties and significantly improve the performance of such machines.”
Substitution for “forever chemicals”
Greater sustainability through lightweight materials is one of many approaches adopted to improve the ecological footprint in industrial production. Meanwhile, more attention is turned to environmentally friendly alternatives for the so-called “forever chemicals”. The focus is on environmentally harmful per- and polyfluoroalkyl substances (PFAS), which are used in production, particularly where extreme conditions prevail: high temperatures, significant wear or aggressive chemical conditions. PFAS can be found in seals, pipes or fittings.
“There is no blanket answer to the question of whether a substitution of PFAS is possible, and an individual assessment must be carried out depending on the application,” says Frank Schönberger, Head of Synthesis and Formulation at the Fraunhofer Institute for Structural Durability and System Reliability LBF from Darmstadt. “A 1:1 replacement of fluoropolymers is generally not possible but always depends on the individual requirements of the respective application.”
There are situations where a fluoropolymer can be replaced with another high-performance polymer (such as PEEK, PEI or PPS) depending on requirements, for example, if temperature and media requirements are moderate or in the area of tribological compounds. “But there are also areas of applications where the complex requirements – nowadays – cannot be fulfilled by any other material,” adds the researcher. “Fluoropolymers have, to a great extent, universal chemical resistance and have high-temperature resistance. In applications where this is required, such as in pumps or machines that have to withstand different media in varying conditions, up to now, fluoropolymers do not need to be replaced,” sums up Schönberger and adds, “There may be opportunities in applications where the full potential of the fluoropolymers is not required and in situations where, e.g., a redesign is possible.”
PFAS substitution also relevant for the USA
According to Schönberger, the PFAS substitution is also relevant for markets outside Europe, in particular the USA. In the USA there are also regulations, in part dependent on the respective federal state. This also shows that greater sustainability in production technology is a global challenge, to which a response must be provided in the factories in all industrial nations.
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Thriam Toolroom has completed a complex family injection mould project in 26 days, setting a new benchmark for the industry. The project, characterised by tight tolerances and sophisticated design, was achieved through advanced manufacturing capabilities powered by Haas, Fanuc, and Mitutoyo technologies.
In a resounding display of efficiency and technical process, Thriam Toolroom, a rising force in the mould manufacturing sector, has shattered conventional timelines by completing a complex family injection mould project in an astonishing 26 days. This feat, achieved amidst the intricate demands of tight tolerances and a sophisticated design, marks a significant milestone for the company and sets a new benchmark for the industry. The project, characterised by its intricate design and stringent specifications, presented a formidable challenge. Thriam Toolroom’s success in navigating these complexities underscores its commitment to innovation and precision. The company’s advanced manufacturing capabilities, powered by a robust machine lineup featuring Haas, Fanuc, and Mitutoyo technologies, played a pivotal role in achieving this remarkable turnaround time.
Minu Madhukumar, CEO of Thriam Toolroom, expressed immense pride in the team’s accomplishment, stating, “We are now at our highest conviction towards achieving plastic mould manufacturing in 21 days after this achievement because what seemed impossible to everyone now looks clearer to us. Proud of the entire team, this success is theirs.” This statement reflects the company’s unwavering ambition to redefine industry standards and push the boundaries of what is achievable in mould manufacturing.
This achievement highlights Thriam Toolroom’s technical capabilities and reinforces its strategic vision to position itself as a leader in timeline-orientated mould manufacturing. The company’s focus on speed and efficiency is driven by a deep understanding of the critical importance of time-to-market for its clients. By accelerating the mould manufacturing process, Thriam Toolroom empowers its customers to reduce their product development cycles and gain a significant competitive advantage.
Thriam Toolroom’s commitment to delivering exceptional results is rooted in its state-of-the-art facilities and a team of highly skilled professionals. The company’s investment in cutting-edge technology and its dedication to continuous improvement enable it to handle even the most complex projects with unparalleled efficiency and precision.
The company’s ability to achieve such rapid turnaround times is a testament to its streamlined processes and optimised workflows. By leveraging advanced CAD/CAM software, employing lean manufacturing principles, and maintaining rigorous quality control measures, Thriam Toolroom ensures that every stage of the manufacturing process is executed with utmost precision and efficiency.
Furthermore, Thriam Toolroom’s emphasis on collaboration and communication ensures that its clients are kept informed throughout the entire process. This transparent and customer-centric approach fosters strong relationships and builds trust, reinforcing the company’s reputation as a reliable and dependable partner.
In a market where time is of the essence, Thriam Toolroom’s ability to deliver molds in record time provides its clients with a significant competitive edge. By reducing time-to-market, the company enables its customers to launch new products faster, capitalize on market opportunities, and ultimately drive growth.
As Thriam Toolroom continues to push the boundaries of innovation and efficiency, it is poised to become a leading force in the mould manufacturing industry. The company’s unwavering commitment to lead time, speed, and customer satisfaction sets it apart from its competitors and positions it for continued success. By consistently delivering exceptional results, Thriam Toolroom is helping its clients achieve their goals and thrive in today’s dynamic marketplace.
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Viksit Bharat 2047 envisions the country becoming a $30 trillion economy. Women comprise around 27% of the overall workforce across all industries. To reach the $30 trillion goal, manufacturing must play a significant role, as the service industry is already contributing. A mere 10% increase in women’s participation in manufacturing could boost India’s GDP by $750 billion.
The service sector generally has better representation compared to the manufacturing sector. In a candid conversation with Neelam Pathak from WIMA, Shailendra Shukla from Eaton highlights that the primary reason for this disparity is manufacturing’s limited appeal to talented individuals, particularly women. Factors such as job ease and the challenge of balancing dual responsibilities are vital. Most importantly, the sector’s working policies need to be addressed.
Neelam: The labour force participation rate shows that women’s involvement in the manufacturing sector in India is limited to around 8-12%. This is low compared to global averages in other industries. What are the factors that hinder women’s participation in this sector?
Shailendra: Manufacturing is a distinct field with different roles, yet women’s participation in India remains low across many areas. Interestingly, participation rates vary by region. I have noticed that plants in the southern region have over 50% female involvement, while in some other region plants may have rates as low as 25%.
One obstacle is the societal and familial environment. Many women work primarily to support their families, leading them to choose jobs that allow them to juggle home responsibilities alongside their careers.
Additionally, company policies often restrict women from working night shifts, further, limiting their opportunities in manufacturing.
Education is a powerful force driving progress. With the gender ratio in education improving, women’s participation in STEM subjects is steadily growing. There is an exciting opportunity to empower women to pursue and excel in technical fields. The manufacturing sector holds immense potential to attract top talent by fostering interest in essential courses and creating an environment where women can thrive, even in physically demanding roles.
To address these challenges, we can enhance educational initiatives to attract diverse talent, promote the manufacturing sector, and encourage companies to take conscious steps toward inclusivity. While this will require deliberate effort, it can lead to meaningful progress.
Neelam: Eaton has been actively promoting diversity and inclusion through various initiatives. How do you encourage women to participate and how can other industries adopt similar practices?
Shailendra: Eaton takes immense pride in being recognized as one of India’s top 10 best companies for women for the past five years. Additionally, our commitment to inclusivity has earned us a place on the Inclusive Companies Index for the second consecutive year.
In India, we prioritize education through our ‘Shalini Program’, which supports students in collaboration with NGOs throughout their educational journeys. We also focus on female students in STEM programs with our ‘Pratibha scholarship’, creating pathways for young women to enter rewarding careers in manufacturing.
Eaton’s operations in the country include a global innovation center and seven manufacturing plants. Additionally, our Women Adding Value At Eaton (WAVE) initiative attracts, retains, and develops female talent.
At our Ahilyanagar plant in Maharashtra, we initially faced challenges in enrolling women for the third shift due to prior restrictions. However, after obtaining government approval, we actively worked to address safety concerns by inviting women and their families to tour the facility, fostering trust and confidence. Additionally, we ensured secure transportation by providing reliable transit directly to their homes, emphasizing their safety.
These efforts have attracted many women for the third shift, resulting in high productivity and quality. We believe supporting women in the workforce is both morally and economically beneficial. Additionally, we ensure a supportive environment to foster their growth, which has enabled us to recruit talent from remote areas, including the Northeast region.
Neelam: Skilling and upskilling are essential for advancing one’s career, regardless of gender, especially in today’s technological era. However, while we have seen many women in operational roles, their presence diminishes at leadership levels and technical positions. What skilling programs does Eaton offer to support women’s journey toward technical and leadership roles?
Shailendra: Skilling should be at the core of an organization. We are living in interesting times; traditional manufacturing methods are no longer effective. We see the significant impact of digitalization on the manufacturing sector. There are discussions about how Industry 4.0 may lead to job losses, bringing in the need for reskilling and upskilling for everyone.
Eaton has a skilling program designed for different job roles. Our innovative approach includes a skilled gym and dojo room in each of our plants, where every new hire undergoes hands-on simulated training for more than 20 days to prepare them for the shop floor. We focus on their ongoing development through various training courses and promote those who upskill themselves to leap with their careers.
In some of our plants, 3D printing initiatives are led by women, and similarly, our quality initiatives are spearheaded by women. Women are now taking up key roles in departments like finance and other fields.
Neelam: According to labour force participation and WEF data, 20 to 25% of women leave their careers due to a lack of mentorship, networking, and guidance, particularly during critical life-changing moments. Character, aspirations, and work-life balance also play significant roles in this decision. How is Eaton supporting women through mentorship, networking, and career guidance?
Shailendra: The issue is that few women quit mid-career, often due to familial obligations at work and home prioritizing their spouse’s career, leading to sacrifices of their own.
While there are cases where women take the lead in taking and accepting transfers, these instances are still rare. Maternity experiences and societal expectations, particularly in India, also present challenges. Many women take sabbaticals to support their children’s education during critical years.
To address this, we have a ‘ReLaunch’ program for attracting women who want to re-enter the workforce after taking career breaks. We support women on maternity leave for a smooth transition back to work, with a break of six months and in some cases upto nine months and during this, colleagues often step up to fill the gaps.
Eaton also prioritises safety and security in our workplace, maintaining strict policies against inappropriate behavior and providing specialised training for upskilling and promotions. These efforts have led to several female leaders breaking the midlife career barrier.
Neelam: If you had to advise women who aspire to enter this industry, or to those who are already part of it, what guidance would you offer?
Shailendra: I want to emphasise the significant growth and learning potential in manufacturing. While growth is important, the learning capacity is even more valuable, as success factors can differ for individuals.
My advice to the next generation is to stay open to opportunities beyond the obvious trends, especially in areas like artificial intelligence and information technology. Gaining domain expertise through hands-on experience in the manufacturing sector is crucial, as it makes you invaluable in knowledge and execution.
A broader perspective is important. Pursuing expertise in manufacturing allows for diverse learning opportunities and potential rewarding career. This industry offers a unique sense of fulfilment, as you’re constantly looking for ways to improve, which extends to your personal life as well.
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Chitale Bandhu’s iconic bakarwadi from Pune needs no introduction. But behind this beloved snack lies a rich legacy that dates back to 1939, when the Late Bhaskar Ganesh Chitale started a milk distribution business in the Sangli district. In the 1950s, Raghunath Chitale extended to establish Chitale Bandhu Mithaiwale. Chitale Bandhu envisioned meeting the growing demand for food products and reducing the need for expensive foreign investments.
OEM Update had the opportunity to step inside the heart of this legacy—the renowned Chitale Bandhu factory—alongside Indraneel Chitale, Managing Partner at Chitale Bandhu. We got an exclusive look at how tradition meets technology, as they have fully automated their bakarwadi-making process, ensuring consistency, efficiency, and the same irresistible taste that has won hearts for generations.
As we step onto the sprawling 20-acre Ranje manufacturing unit of Chitale Bandhu in Pune, Maharashtra, the aroma of freshly prepared sweets and snacks fills the air. This is no ordinary facility—it is a testament to decades of resilience, innovation, and an unwavering commitment to quality. From its humble beginnings in 1939, when Bhaskar Ganesh Chitale founded Chitale Dairy, to its evolution into a globally recognised brand present in 65+ countries, the company has embraced change while preserving its traditional essence.
Automating future of FMCG
Our journey begins at the bakarwadi production unit, where an astounding 17,000 kg of bakarwadi is manufactured daily. What is surprising? The lack of human intervention. The entire process is largely automated—a handful of workers feed raw materials at the start, and another few oversee packaging at the end. Everything in between, from shaping to frying to quality control, is handled by high-tech machinery. Adjacent to this facility is the sweet-making unit, where traditional delicacies like gulab jamun and kaju katli are produced. Here, too, human intervention is limited to the initial and final stages—ensuring that the process remains efficient, consistent, and error-free.
Pioneers in automation
Chitale Bandhu is the first company to fully automate the bakarwadi production process. Indraneel Chitale, Managing Partner and the third-generation leader, explains their approach: “Our focus is on automating processes prone to errors. The goal is not to replace human labour entirely, but to enhance quality assurance, consistency, and efficiency.”
While automation demands heavy investment, it pays off in terms of brand value and consumer trust. In the FMCG sector, where quality consistency is paramount, the investment in cutting-edge foreign-manufactured equipment ensures strict compliance with food safety regulations—something Indian manufacturers are gradually catching up on.
Data-Driven Decision Making
A remarkable 80% of the new facility is automated, requiring massive data collection and analysis. Every process, from ingredient input to packaging, is tracked via IoT sensors, PLC systems, and advanced analytics. This data helps Chitale Bandhu improve efficiency, optimise costs, and maximise profit margins.
The company partners with third-party industrial automation experts to maintain real-time visibility of every operational detail. Each machine’s efficiency is tracked as a key performance indicator (KPI) to ensure optimal production output and minimise wastage.
Inventory and Quality Control
Inventory management at Chitale Bandhu is a fine-tuned science. Unlike traditional FMCG businesses, they prioritise high inventory turnover over stockpiling. Through software-driven analytics, they determine what to produce, when, and how much—ensuring that customers always receive the freshest products.
Their SAP-integrated quality control system tracks each batch from raw material procurement to post-sale analysis. Products undergo rigorous testing throughout their shelf life, with complete traceability—a feature essential in maintaining global standards.
Machine Maintenance & Performance Incentives
Machine uptime is closely linked to employee performance incentives. The maintenance team operates like a Formula One pit crew, ensuring minimum downtime and maximum efficiency. Preventive maintenance is prioritised over breakdown repairs, utilising IoT sensors to track wear and tear in real time.
He says, even during the off-season, machines operate 18–20 hours a day, with just four hours of downtime. During peak seasons, downtime is reduced to two hours daily, solely for deep cleaning and maintenance.
A Culture of Safety and Excellence
At the heart of Chitale Bandhu’s success is its deep respect for food—a philosophy rooted in Indian tradition. Every visitor and worker follows strict hygiene protocols, wearing PPE kits to prevent contamination. Their food manufacturing process reflects the ethos of purity and quality, ensuring that customers receive nothing short of the best.
R&D and Future Vision
Chitale Bandhu’s in-house Research & Development (R&D) team focuses on three key areas: researching new technologies to improve production methods, developing new products to meet evolving consumer preferences, and innovating critical processes to enhance quality and efficiency. Over the past five years, the company has invested over ₹200 crores in expanding operations, upgrading technology, and generating employment. What began with just 20 employees has now grown to a workforce of 600, with a vision to reach 1,000 shortly.
Betting on Bars
Looking to the future, Chitale Bandhu is focusing on bars—a format expected to dominate the snacking industry in the coming decade. Their namkeen bars, health bars, protein bars, and fruit bars are already gaining traction.
“Our goal,” Indraneel shares, “is to make Chitale Bandhu a gateway brand—one that appeals to diverse nationalities while enhancing nutritional value.”
As we conclude our tour, we are left mesmerised by the seamless blend of tradition and modern innovation. The automation, IoT integration, precision tracking, and sustainability initiatives make Chitale Bandhu a benchmark in the global FMCG industry.
What once started as a small dairy business is now a pioneering food-tech enterprise—continuing to uphold its rich legacy while shaping the future of food manufacturing.
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Sustainability is a growing focus in the food industry. How does Chitale Bandhu incorporate circular economy principles to manage its production processes?
Wherever food is produced, there are likely to be many rejections after the completion of the product due to various issues that may arise. Some of these problems are unavoidable process errors, and they are addressed by the team. We at Chitale Bandhu follow the concept of the circular economy. The approach involves a mix of solutions to ensure that waste is not completely lost. Every process will generate a certain amount of waste, and one of our key performance indicators (KPIs) focuses on how we can keep that waste within manageable limits. Another KPI is how we can utilise this waste productively. Instead of throwing it away and rendering it unusable, we strive to find ways to give it a second life.
There are three key factors to consider. One is product wastage. Some items can be reused, while others cannot. It’s essential to manage product waste and keep things under control.
Another aspect is water treatment. A significant amount of water is used to clean food equipment. At Chitale Bandhu, this water is treated properly and released in a controlled manner.
Packaging helps Chitale Bandhu reach its consumers, but materials designed to preserve products are often not biodegradable. More sustainable packaging that is reliable and possesses adequate rigidity is under consideration. This includes ensuring a reasonable thickness so that it can be handled by recycling equipment. Additionally, we are exploring options for co-extruding layers that will allow us to reuse plastic, thereby reducing waste.
Chitale Bandhu has made significant strides in energy efficiency and sustainability. Can you share how your Ranje unit is achieving an energy surplus?
From an energy perspective, our Ranje unit is operating at a surplus. In terms of water use and achieving zero discharge, we are nearly 90% of our targets. However, we are yet to work on effectively addressing plastic waste and zero-discharge state. Our goal is to improve efficiency and comply with the requirements of net-zero manufacturing over time.
The premise sources nearly 60% of its energy supply from solar power. We are also investing in wind farms and utilising open access to lower electricity costs, which is a significant expense for us as manufacturers, especially in Maharashtra.
By being efficient in our manufacturing processes, we can reduce our overall costs. Utilising renewable energy is the primary way we are managing these expenses. All entities within the Chitale Group are actively engaged in initiatives related to renewable energy.
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Millenia Technologies made a strong impact at IMTEX 2025, one of India’s largest manufacturing expos. As a leading supplier of high-precision surface technologies, the company highlighted its diverse range of machines catering to industries like jewelry, cutting tools, medical implants, automobiles, and aerospace.
With over a decade of expertise, Millenia Technologies has built a strong reputation for delivering high-quality products, cost-effective solutions, and top-notch service. Committed to customer satisfaction, the company ensured that any machine-related issues were resolved within 24 hours, reinforcing its dedication to seamless operations across India.
The company collaborates with renowned European brands such as Bernex, Rosler, Hauzer, and Bruker Alicona, reinforcing its position as a trusted partner for high-performance manufacturing solutions in India.
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