Steering the automotive industry towards sustainability

Novelis, the wholly-owned subsidiary of Hindalco – Aditya Birla Group’s flagship metals company has been a driving force steering automakers, and their customers, towards a future where vehicles are lighter, safer, and above all, greener. The world’s largest recycler of aluminium makes a strong case for use of the versatile material to address challenges faced by the automotive industry today.

The Aluminium Advantage

• Lighter
• Simpler 
• Safer
• Greener

Leveraging lightweight

Vehicles made with aluminium are significantly lighter than those made with steel, reducing energy consumption. When it comes to electric vehicles (EVs) as well, reduced weight translates into extended battery range, fewer batteries, and smaller engines, suspension systems and brakes —leading to additional cost savings for automakers.

Aluminium-intensive body-in-white (BIW) structures weigh up to 45% less than steel-intensive vehicles, enabling automakers to improve performance and increase payload capacity.

Simplifying production

Aluminium's versatility supports modular design and manufacturing efficiencies, helping automakers streamline production across vehicle segments. Fewer total parts mean reduced robots, tools, and joints, resulting in improved assembly efficiency and lower factory emissions. Using aluminium also reduces the complexity of material grades compared to steel while achieving similar functionality. These efficiencies reduce downstream supply chain requirements, simplify manufacturing complexity, and create value for automakers.

Improving safety

High-strength aluminium alloys deliver exceptional crash performance, protecting occupants while still allowing for vehicle weight reduction. Additionally, aluminium's lightweight properties enhance vehicle dynamics, improving handling, braking, and acceleration—essential features for safer driving experiences.

Aluminium demonstrates better energy absorption, allowing vehicle architectures to be engineered for improved occupant protection, and contributing to high marks in 5-star crash safety testing.

Greening the future of mobility

As the world's leading provider of low-carbon, recycled aluminium, Novelis enables automakers to design vehicles with lower lifecycle emissions, aligning with carbon reduction goals. For internal combustion engine vehicles, lighter vehicles produce fewer emissions and require less fuel during operation, while for EVs, fewer batteries or smaller battery packs greatly reduce the vehicle's carbon footprint.

Additionally, aluminium's infinite recyclability creates opportunities for a more circular economy, through the recovery of aluminium in body and battery enclosure systems at the end of the life of the vehicle. Reusing recovered aluminium scrap significantly reduces the need for primary aluminium production, leading to substantial environmental benefits.

Recycling aluminium consumes only about 5% of the energy required for primary production, resulting in up to a 95% reduction in energy usage and a similar percentage reduction in greenhouse gas emissions.

Driving towards a sustainable tomorrow

The demand for lighter, greener, simpler, and safer vehicles will continue to grow as consumers and regulators prioritise sustainable mobility. For automakers, the transition to aluminium should not be seen as a challenge but as an opportunity for achieving the automotive industry's long-term goals.

As a part of the Aditya Birla Group, Novelis brings with unmatched expertise, innovative solutions, and commitment to sustainability, Novelis is ready to empower automakers to create vehicles that meet today's demands and anticipate tomorrow's challenges and together drive the automotive industry toward a more sustainable, efficient, and prosperous future.