### **Overview** UCAL Limited (formerly UCAL Fuel Systems Limited) is a leading Indian automotive component manufacturer with nearly four decades of engineering excellence. Founded in 1985 as a joint venture with Japan’s Mikuni Corporation, UCAL has evolved from a carburetor specialist into a diversified technology-driven company focused on **mechatronic systems, automotive electronics, emission control, precision casting, and electric vehicle (EV) components**. The company serves over **35 global OEMs**, operates advanced manufacturing and R&D facilities in **India and the United States**, and is actively transforming into a sustainable, multi-industry solutions provider. Under the leadership of **CEO Mr. Abhaya Shankar**, UCAL launched **“U-RISE”** – a five-year transformation roadmap aimed at accelerating revenue growth, reducing customer and product dependency, and expanding into new geographies and technology frontiers. --- ### **Strategic Transformation: U-RISE Program** - **Launched in FY2023**, U-RISE is a comprehensive strategy to **diversify revenue streams**, enhance innovation, and future-proof the business. - Key Focus Areas: - Reduce reliance on a few customers, products, and regions. - Expand into multiple customer segments in **2-wheelers (2W) and 4-wheelers (4W)**. - Broaden **electronic product offerings** and **aftermarket distribution**. - Grow **exports** and deepen global OEM partnerships. - The initiative has led to a **four-fold increase in RFQs** and a robust new order pipeline. Organizational restructuring under the CEO emphasized agility, accountability, and customer-centricity, including: - Implementation of a **Key Account Management (KAM) system** for OE sales. - Establishment of a **Project Management Department** to accelerate development cycles. - Hiring of domain experts in **electronics R&D** and strengthening of supply chain and sales functions. --- ### **Core Business Segments & Capabilities** #### **1. Mechatronics & Automotive Electronics** UCAL is now positioned as a **total mechatronic solutions provider**, integrating mechanical, electrical, electronic, and software engineering to deliver advanced automotive systems. - **Product Portfolio Includes:** - Electronic Fuel Injection (EFI) Systems - Engine Control Units (ECUs) – developed via collaboration with global and Japanese OEMs - Electronic & Mechanical Throttle Bodies - Accelerator Position Sensors (APS), Gear-Neutral Sensors, Vacuum Sensors - Smart Intake Throttle Valves, Fuel Rails, Hydrocarbon (HC) Dosers - Oil, Vacuum, and E-Coolant Pumps for ICE and EV platforms (BEV, HEV, PHEV, FCEV) - Electronic Control Modules: Flashers, E-Horns, Wiper Timers, CDIs, Rectifier Regulators - **EV-Focused Innovations (2024):** - Launched a range of **EV-specific electronics**, including DC-DC Converters, Motor Controllers, Traction Inverters, BLE-enabled systems, and GoHome Modules. - Developed **integrated sensors** combining MAP, IAT, and TPS for improved vehicle diagnostics and efficiency (aligned with BS-VI OBD-II Stage B requirements effective April 2025). - **R&D Infrastructure:** - **KCAT (Krishnamurthy Centre for Automotive Technology)**: DST-recognized and NABL-accredited R&D center with advanced simulation, testing, and prototyping capabilities. - Dedicated **Electronics R&D Division** in Pune with domain experts in software, hardware, and embedded systems. - Strategic collaborations with a **global auto OEM** and an **engineering design firm** to co-develop next-gen ECUs and electronic systems. - **Electronics Manufacturing:** - State-of-the-art **ESD-protected plant in Pune** with full-service capabilities from design to pilot launch. - Compliance with international standards (100K Class DVP, EMI/EMC). - Patents pending on multiple EV-related innovations. --- #### **2. Casting & Precision Machining** A core strength, especially with growing global demand for **lightweight, complex, high-precision components** in automotive, aerospace, defense, and industrial sectors. - **Backward Integration Model:** - **Casting**: High-pressure and vacuum die-casting facilities across India. - **Machining**: Advanced sub-micron precision facility in **Elgin, Illinois, USA**, capable of machining parts from 3mm to 100mm using ferrous and non-ferrous alloys. - **Recent Expansions:** - Supplied **high-precision machined parts** to leading US engine OEMs and domestic auto majors. - Exported **heavy-duty components** including HD Injector Throttle Bodies and High Tonnage Crank Case Castings. - Secured major export orders for **titanium pump housing sleeves**, diesel fuel injection components, and **build-to-print** OEM parts. - **Capable Across Industries**: Automotive, Aerospace, Defense, Marine, Hydraulics, Appliances. --- ### **Growth Initiatives & Diversification** #### **Expansion into EVs, Hydrogen & Alternate Energy** - Actively developing technologies for: - **Electric Vehicles (EVs)**: Traction motor controllers, EV ECUs, smart pumps. - **Hydrogen Applications**: Electric throttle bodies for CNG/hydrogen commercial vehicles; exploring **hydrogen combustion systems**. - **Fuel Cell Vehicles (FCEVs)** and **charging infrastructure**. - **MoU with Blaer Motors** to jointly develop **500W–2kW motor controllers** for EVs. - Aligning with India’s **Hydrogen Fuel Policy** and global decarbonization goals. #### **Global Market Expansion** - Exports to **US, ASEAN, Latin America, South Africa, Japan, and Poland**. - Supplies components to Indian OEMs exporting vehicles to **75+ countries**. - Expanded global distributor base by appointing **~70 new distributors** in 2024, including a key US-based partner with presence in **30 countries**. - Identified **Asia-Pacific** as a high-growth market due to urbanization and rising auto demand. #### **Aftermarket & Distribution Growth** - New **Distribution Division** established for direct customer engagement. - Pan-India expansion with new retail touchpoints and mapped 32 additional cities. - Grew **aftermarket sales by 25% (YoY)** through white-labeled products and "Buy & Sell" initiatives. - Launched **"Buy and Sell" business** (February 2024) to offer integrated parts and service solutions. #### **Entry into Drones & New Technology Verticals** - **Acquired Avironix Pvt Ltd** (Feb 2024), a drone design and manufacturing company. - Avironix’s **Peregrine mapping drone** has obtained **Type Certification**, enabling deployment in agriculture, mining, infrastructure, and defense. - Reflects UCAL’s broader strategy to enter **non-automotive, high-tech domains**. --- ### **Sustainability & Regulatory Alignment** - Committed to **green mobility**, **lean manufacturing**, and **zero-defect, energy-efficient systems**. - Products compliant with **BS-VI, OBD-II, and Euro VI** standards. - Launched emission control systems with diagnostic features for real-time monitoring. - Developed **urea dosers, HC dosers, and flex-fuel sensors** for cleaner combustion. - Manufacturing follows **Lean, TPM, SMED, 5S**, and **Industry 4.0** practices (IoT-enabled plants, data analytics). - “**Leaner, Greener, Smarter**” production model to support sustainability goals. --- ### **Financial & Market Position Highlights (FY2024)** - Maintained revenue despite **decline in e-Carburetor sales** due to shift toward EFI systems. - Achieved **21% YoY growth in 2W carburetor sales**; **89% surge in Oil Pump sales**. - Strong new product pipeline: Over **30% of R&D** focused on **anchor products in green energy and EVs**. - Four-fold increase in **RFQs** and expanded order book from global OEMs. - Successfully navigated global headwinds (Russia-Ukraine war, inflation, supply chain issues) with prudent working capital and cost management. --- ### **Leadership & Governance** - **Chairman & Managing Director**: Mr. Jayakar Krishnamurthy (MBA, Duke University), a key figure in building long-term OEM relationships. - **CEO**: Mr. Abhaya Shankar (served from Nov 2022 to Nov 2023, during which U-RISE was launched; ongoing strategic impact). - **Ownership Group**: The UCAL Group includes **Avironix** and continues to operate integrated R&D and manufacturing across India and the U.S. ---