Menon and Menon Ltd (MML), an established leader in manufacturing automotive grey iron castings such as cylinder blocks and heads, is making significant strides in its technological journey. With over 60 years of experience, the company has consistently innovated in both products and processes, ensuring its growth and success in the industry. The company has partnered with SinterCast, the global leader in Compacted Graphite Iron (CGI), to advance its product development. It is expanding its capabilities by integrating SinterCast’s Mini-System 3000 into its Kolhapur foundry, marking the start of a significant trial phase for CGI production.
The system has already produced high-quality CGI microstructures that meet the international ISO 16112 standards, signalling a successful start. Following installation and training, MML is now independently refining its processes and delivering validation castings to international clients in the on-road and off-road sectors. The trial will continue through 2025, after which MML will review progress with SinterCast to plan the next steps for full-scale production.
The company currently supplies to a wide range of clients, including Ashok Leyland, John Deere, Mahindra, Escorts, TAFE, Sonalika, Same Deutz-Fahr, Mitsubishi, Tata Motors, Force Motors, Arrow Engine, Greaves, Isuzu, and BEML.
Growing Global Footprint
MML has made remarkable strides in the global automotive sector, largely due to its commitment to high-quality, cost-effective manufacturing. Speaking to Mobility Outlook, Vijay Menon, Managing Director, MML, said that the company was able to demonstrate its capabilities and exceed expectations when one of India's leading OEMs – Mahindra & Mahindra, initially had doubts about the ability to produce high-quality blocks domestically. Initially importing blocks from China, the OEM was hesitant about indigenising production. However, after MML's successful trials, the company was pleasantly surprised by the lower defect rates and better performance of the locally produced blocks. This marked the beginning of a shift, with the OEM now sourcing the entire block and head from MML.
In addition to the OEMs automotive division, MML’s involvement with tractor manufacturing division has grown, with the company now producing 100% of cylinder blocks for certain tractor models. The collaboration with Mahindra, Tata Motors, and John Deere has also opened doors to new markets, particularly in exports. While John Deere's operations in India may be limited, the company purchases parts for its global operations, further boosting MML’s export business.
The company has also recently begun exporting to a German customer, with further expansions expected as John Deere’s validation, testing, and approval processes continue. This marks a significant step towards establishing a stronger international presence. What sets MML apart, according to the MD, is its rare combination of Indian cost structure and the ability to meet western-quality demands, making it an attractive partner for global customers.
MML is not only driving innovation in automotive casting but is also leading the way in sustainability. As global companies increasingly demand eco-friendly castings, MML is responding proactively by making significant investments in renewable energy. The company has already invested in a 1 MW solar plant at its Kagal plant, along with a larger 6 MW solar facility located offsite.
Currently, around 27% of its energy comes from renewable sources, including solar power, wind energy, and biogas. But the company isn't stopping there. MML has ambitious plans to expand its solar power capacity to a total of 36 MW as its production capacity grows, making sustainability a key focus in its future growth.
Through these investments, MML is not only reducing its environmental footprint but also paving the way for more sustainable manufacturing practices, aligning with the increasing demand for eco-friendly solutions in the global market. This commitment to renewable energy is set to position it as a leader in both product quality and environmental responsibility, supporting the company’s long-term vision of growth in an increasingly eco-conscious world, he said.
Strategy Amidst Shift To E-Mobility
With the rise of e-mobility, the inevitable decline of internal combustion engines (ICE) raises a critical question—what happens next? Instead of reacting hastily, MML took a strategic approach, engaging with customers and R&D teams in India and abroad. The consensus was clear: for the next 15 to 20 years, the company’s existing product line remains secure. Given that manufacturing plants typically have a return on investment of around 10 years, the current expansion plans align well with long-term business sustainability.Looking beyond this horizon, the company aims to leverage India's cost advantages and expertise in large castings to expand its global market share. Even in a shrinking ICE market, capturing a larger portion of the business can ensure continued growth, he said. However, the company is not solely reliant on ICE.
Recognising the shift towards alternative mobility solutions, it has proactively invested in hydrogen and fuel cell technologies. Over the past two years, it has worked closely with Tata Motors and initiated discussions with Mahindra to advance technology trials. By gradually seeding the market, the company is positioning itself for the future without taking undue risks.
Unlike larger conglomerates that can dictate technological trends, MML adopts a pragmatic approach. Rather than betting on a single technology, the company aims to maintain a foothold in both electrification and hydrogen, ensuring relevance regardless of the direction mobility takes.
Opportunities In Battery Casings
One key area of focus is battery safety. As battery power density increases, so does the risk of fire and explosion. Battery casings are evolving from simple carriers to critical safety components designed to protect passengers and provide crucial evacuation time. To meet stringent future regulations, the company is exploring advanced metallurgy and cooling circuit designs. Currently, most battery casings are manufactured using pressure die-casting. However, the company is exploring a patented casting technology that retains the lightweight advantage of aluminium while achieving the strength of forged components.
Successful adoption of this technology would enable the company foray in to non-ferrous segment and supply lightweight, high-strength parts to two-wheeler OEMs looking to replace iron-forged components. Though these technologies are still in the early stages, the company is committed to proving their viability over the next few years. By establishing an early presence in these emerging fields, the company “aims to create a strong entry barrier, much like the foundry business today, where high capital investment and long validation cycles prevent new competitors from easily entering the market,” he explained.
The same strategic foresight applies to the company’s approach to hydrogen. With ongoing projects and investments in this space, it is ensuring that when the industry transitions, it will not be starting from scratch but will already have a stake in the future of mobility.
Fuel Cells & Advanced Materials
Vijay Menon said MML is actively working with UK-based start-ups to develop more cost-effective fuel cell technology. Significant progress has already been made in reducing costs, and the company is collaborating with Tata Motors to validate these advancements through proof-of-concept testing. While the testing and validation phase could take two to three years, the company is positioning itself early in this emerging sector, ensuring that when the shift happens, it is ready. The next 5 to 10 years could be a defining period, balancing growth in its existing business while expanding into next-generation technologies.
While the traditional ICE industry will continue to exist for the next 15 to 20 years, its growth trajectory is expected to slow. Instead of the 20-30% growth rates seen in the past, industry expansion may be closer to 5-6%. However, MML strategy is clear: increase market share by offering customers cost and quality advantages, expand globally, and ensure its manufacturing capacity remains fully utilised. Meanwhile, cash flows from the core business are being strategically reinvested in new-age technologies, laying the groundwork for long-term success.
By securing a strong position in both emerging and traditional markets, MML is not only safeguarding its present but also future-proofing its business against the inevitable transformation of the mobility industry.
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