Mahindra Starts Developing Flex Fuel Engines: Details Inside

KEY HIGHLIGHTS

Mahindra develops flex-fuel engines for E30.
Ethanol-resistant materials ensure engine durability.
Heated injectors aid cold-start performance.
XUV300 flex-fuel prototype matches petrol performance.
Ethanol blends may reduce fuel economy.

India's journey toward cleaner and more sustainable mobility has entered a new phase, with ethanol-blended fuel forming a key part of the government's long-term strategy. While concerns about the technical challenges of higher ethanol use remain, the shift towards E30 fuel by 2030 is already shaping the plans of major automakers. Mahindra, in particular, has begun preparing its SUVs for the future by developing flex-fuel engines that can seamlessly adapt to multiple ethanol blends. Check out what Mahindra is cooking in its R&D centres below and make sure you join our 91Wheels WhatsApp Community to stay versed on the latest automotive news.

Mahindra's Flex-Fuel Strategy

As one of the leading SUV manufacturers in the country, Mahindra is taking a proactive stance on the ethanol transition. The company is working on new-generation engines that won't just be compatible with the current E20 fuel (already mandatory for all cars manufactured from April 2023) but will also be ready for E30 blends and beyond. The move is a step toward ensuring long-term durability and compliance with upcoming emission and fuel standards.

What Would Be Different in Flex Fuel Engines?

Reports suggest that Mahindra's flex-fuel engines are being designed with ethanol-resistant materials such as stainless steel, treated aluminium and advanced polymers. These are necessary because ethanol tends to corrode traditional components like fuel tanks, injectors, and hoses over time. By adopting more robust materials, Mahindra aims to protect its engines from wear while ensuring consistent performance.

Engineering Changes for E30 Compatibility

Running a vehicle on higher ethanol blends isnt as simple as just recalibrating the ECU. Ethanol, being more corrosive and having a higher ignition temperature than petrol, demands extensive reengineering of engine systems. For instance, Mahindra is expected to incorporate heated injectors and fuel rails, which would help in achieving proper vaporization during cold starts. Additionally, sophisticated ethanol content sensors will be integrated into the system. These sensors allow the ECU to adjust fuel injection, spark timing, and air-fuel ratios dynamically based on the blend of ethanol being used.

Another crucial challenge lies in component degradation. Rubber seals, gaskets, and hoses that work fine with petrol often deteriorate rapidly when exposed to ethanol. Mahindra's solution is to replace these with modern, ethanol-proof alternatives. ECU software upgrades are also being worked upon to optimize combustion efficiency, ensuring that engines can handle anything from regular petrol to blends as high as E85.

Prototypes and Early Showcases

This isn't Mahindra's first brush with flex-fuel technology. The company had already demonstrated a flex-fuel version of the XUV300 at the 2024 Bharat Mobility Expo. That prototype ran on ethanol blends ranging from E20 to E85, yet managed to deliver the same output figures - 110 hp and 200 Nm as its standard turbo-petrol counterpart. Such showcases highlight the brand's capability to adapt its current powertrains to greener alternatives without compromising performance.

Addressing Efficiency and Cost Concerns

While flex-fuel vehicles are promising in terms of sustainability, they aren't without drawbacks. Ethanol has a lower energy density compared to petrol, which directly affects fuel economy. Studies suggest that mileage could drop anywhere between 15-30% when running on higher ethanol blends. To counter this, Mahindra will have to focus heavily on calibration.

Production cost is another area that could see an upward shift. Stronger materials, redesigned injectors and advanced electronics naturally push up manufacturing expenses. However, Mahindra appears to view these costs as long-term investments, positioning itself as an early mover in a market that will eventually demand ethanol-ready powertrains.

Verdict

Mahindra's push into flex-fuel technology marks an important milestone for both the brand and the Indian auto industry. With government timelines pointing firmly toward E30 by 2030, manufacturers that prepare in advance will be best positioned to meet new regulations and customer needs. Mahindra's initiative shows that the shift towards greener fuel alternatives is no longer just a future possibility - it's a roadmap that is actively being built today.

Source: Autocar India