Hyundai India Adopts 100% Fuel-free Engine Testing
The company tests over 4.25 million engines with zero-emission Cold Bed Engine Testing technology, without using any fuel, coolant or water
Hyundai Motor India Limited (HMIL), on Monday, said that it has tested over 4.25 million engines using cold bed technology without fuel, coolant, or water—curbing over 2 million kg of CO₂ emissions and saving $1 million in resource costs. All engines now undergo automated, zero-emission quality checks. Cold Bed Engine Testing technology - a process that eliminates the need for fuel, coolant, and water.
Gopalakrishnan CS, Whole-time Director and Chief Manufacturing Officer, HMIL, said, "At Hyundai Motor India, we constantly push the boundaries of innovation to deliver world-class quality while championing sustainability. By successfully testing over 4.25 million engines using zero-emission Cold Bed Engine Testing technology, we have significantly advanced our commitment to eco-friendly manufacturing - curbing over 2 million kg of CO₂ emissions and optimising efficiency with US $1 million in operational savings. Our fully automated, fuel-free testing process ensures that every engine meets the highest standards while reinforcing our vision of responsible mobility."
Gopalakrishnan CS, Whole-time Director and Chief Manufacturing Officer, HMIL, said, "At Hyundai Motor India, we constantly push the boundaries of innovation to deliver world-class quality while championing sustainability. By successfully testing over 4.25 million engines using zero-emission Cold Bed Engine Testing technology, we have significantly advanced our commitment to eco-friendly manufacturing - curbing over 2 million kg of CO₂ emissions and optimising efficiency with US $1 million in operational savings. Our fully automated, fuel-free testing process ensures that every engine meets the highest standards while reinforcing our vision of responsible mobility."
Introduced in 2013, Cold Bed Engine Testing allows HMIL to assess engine performance using electricity from renewable sources rather than traditional fuel-based methods. The system employs smart sensors to analyze key quality parameters, ensuring precision without emissions.
The company said that the adoption of fuel-free Cold Bed Engine Testing by Hyundai Motor India has had a measurable environmental and operational impact. By eliminating the use of fuel, the company has prevented over 2 million kg of CO₂ emissions, supporting cleaner air and sustainable mobility. This shift has also led to significant cost savings, with nearly $1 million saved in operating expenses. Additionally, the automated nature of the technology improves testing efficiency, removes the need for manual judgement, and enhances safety compared to traditional methods.
How Does Cold Bed Engine Testing Work?
How Does Cold Bed Engine Testing Work?
Each engine manufactured by HMIL is placed in a Cold Bed Engine Testing station, where an electric motor rotates the crankshaft. High-tech sensors monitor performance parameters, crankshaft angle, engine compression, chamber pressure, and evaluate overall engine worthiness, ensuring top-tier quality without burning fuel. This Industry 4.0-integrated system also stores test data digitally, allowing for future research and development.
Driving the Future of Green Manufacturing
HMIL’s fully automated, zero-emission engine testing process reflects its commitment to sustainability and innovation. As the company continues to set industry benchmarks, this milestone reflects HMIL’s resolve to develop cleaner, more efficient technologies for the future – both in terms of products, and processes.
Cold Bed Engine Testing is one among many instances of HMIL’s constant perseverance for a better future. HMIL has been shaping a smarter and greener automotive industry, in line with Hyundai’s global vision of achieving net zero target by 2045.
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