Interview: Dr. Nilesh Kukalyekar

Business Director - South Asia, Middle East and South Africa at Envalior

From Bio-Based Polymers to Hydrogen Storage: Dr. Nilesh Kukalyekar on Envalior’s Innovations

May 20, 2025. By Abha Rustagi

Envalior builds sustainability into every stage of product development, from material sourcing to end-of-life impact, said Dr. Nilesh Kukalyekar, Business Director - South Asia, Middle East and South Africa, Envalior, in an interview with Abha Rustagi, Associate Editor, Energetica India.

Que: How is the company progressing in its transition to 100 percent renewable electricity across global manufacturing facilities?

Ans: Envalior is actively moving toward using 100 percent renewable electricity in all its global manufacturing plants by 2030. This goal is part of its larger decarbonisation plan to cut Scope 1 and 2 emissions by 75 percent and reach net-zero emissions by 2040. Several European and Asian sites have already begun operating on renewable energy, supported by long-term power purchase agreements and installation of on-site solar panels.

Envalior is also upgrading equipment and processes to lower overall energy use. The company tracks its energy mix and emissions reductions through lifecycle assessment and aligns its climate goals with the Science Based Targets initiative (SBTi). By sourcing green electricity, Envalior not only lowers its operational footprint but also helps OEMs and customers meet their own ESG goals. This transition is especially important for automotive and electronics clients facing growing regulatory pressure for cleaner supply chains. Envalior’s transparent reporting through sustainability updates helps benchmark progress and keeps investors and partners informed.


Que: How are you integrating sustainability into your product innovations? Can you highlight some of the bio-based and recycled material solutions Envalior has developed?

Ans: Envalior builds sustainability into every stage of product development, from material sourcing to end-of-life impact. The company’s bio-based product lines include EcoPaXX®, a high-performance polyamide made from castor beans. This material is carbon neutral and suitable for automotive parts like engine covers and fuel systems. Envalior has also developed Akulon® RePurposed, created from recycled fishing nets collected from coastal areas. It’s used in electronics housings and car components.

The Arnitel® ECO range contains up to 50 percent bio-based feedstock and is used in flexible automotive tubing and soft-touch applications. On the recycled side, Durethan® ECO and Pocan® ECO integrate post-industrial and post-consumer recyclates while still meeting mechanical strength and thermal stability requirements. Envalior uses lifecycle analysis (LCA) to confirm environmental impact reduction and help customers calculate Scope 3 emissions savings. These innovations are developed with a strong focus on circularity, regulatory compliance (e.g., REACH, RoHS), and reliable processing across industries.


Que: With the automotive industry shifting towards a circular economy, how does Envalior help OEMs and Tier-1 suppliers integrate recycled and sustainable materials into vehicle manufacturing?

Ans: Envalior helps automotive manufacturers meet circular economy goals by offering engineering plastics that combine performance with sustainability. Products like Durethan® ECO and Pocan® ECO are designed with up to 60 percent recycled content—both post-consumer PET and industrial scrap. These materials meet critical performance requirements in heat resistance, mechanical strength, and chemical durability for components like brackets, connectors, and under-the-hood parts. Envalior provides technical support during material qualification to help OEMs switch to sustainable grades without retooling.

The company also works with clients on Design for Recycling (DfR) and closed-loop recycling projects. For example, it helps integrate recycled materials into lightweighting strategies to reduce vehicle CO₂ emissions across their lifecycle. Envalior’s solutions are validated under global automotive standards (such as ISO 11469, VDA 231-106), ensuring compliance with OEM sustainability audits and EU vehicle end-of-life directives. These initiatives make it easier for automakers to meet both product performance and environmental compliance goals.


Que: With the rise of EVs, how are Envalior’s materials helping improve battery performance, safety, and range?

Ans: Envalior has developed advanced materials to address thermal, electrical, and structural challenges in EV battery systems. One key innovation is Durethan® BTC, a thermally conductive and flame-retardant polyamide used in battery housings and modules. It helps dissipate heat efficiently while offering high voltage insulation, improving both safety and energy performance. Envalior also provides Xytron™, a PPS-based material with high dimensional stability and chemical resistance, used in battery connectors, high-voltage inverters, and e-motor parts. These materials meet strict fire safety standards like UL 94 V-0 and resist thermal aging, which is critical in high-temperature battery environments.

Envalior showcased a lightweight battery enclosure concept at Auto Expo 2025 that replaces metal with reinforced thermoplastics to reduce weight and extend EV range. The company’s solutions also support fast-charging systems by managing thermal spikes and electrical insulation in compact packaging. This portfolio is designed to help EV manufacturers meet upcoming ISO 26262 safety standards while optimising system design.


Que: Envalior has a strong manufacturing presence in India, supplying both domestic and international markets. What are the key advantages of local production, and how does it support sustainability goals?

Ans: Envalior’s Indian manufacturing sites play a key role in regional and global supply. Local production reduces shipping distances, which cuts transport-related emissions and speeds up supply chain response times. These facilities manufacture high-performance polymers for automotive, electronics, and industrial customers, tailored to local climate and regulatory conditions.

Several Indian sites have implemented solar energy systems and water recycling units, contributing to the company’s global emissions and resource efficiency targets. Envalior also uses local recycling streams in India to produce materials like Durethan® ECO, aligning with national circular economy goals. Having R&D and technical centers on-site allows rapid prototyping and adaptation of global formulations for Indian OEM requirements. This local footprint also helps serve multinational clients sourcing from India, ensuring consistent quality while meeting region-specific compliance standards such as BIS and AIS. Overall, India acts as a model for combining cost-effective production with sustainability-driven material innovation.


Que: Your R&D center in Pune is exploring next-generation materials, including hydrogen storage solutions. Can you brief us about this research and its potential impact on the automotive sector?

Ans: The R&D center in Pune is focused on next-generation mobility materials, including high-pressure hydrogen storage tank solutions for future automotive applications. These tanks need to be strong, lightweight, and resistant to hydrogen permeation. Envalior is developing hybrid thermoplastics reinforced with glass and carbon fibers that meet ISO 19881 and EC79 safety requirements. These materials are designed to replace metal liners and reduce total system weight by up to 40 percent, improving fuel efficiency and range.

The center works in collaboration with international research teams and industry partners to test these materials under real-world conditions. The goal is to enable scalable, cost-effective solutions that support the transition to zero-emission transport in emerging markets.


Que: Looking ahead, what are the next steps in Envalior’s strategy for innovation, sustainability, and market expansion in South Asia, the Middle East, and Africa?

Ans: Envalior’s strategy in South Asia, the Middle East, and Africa focuses on scaling regional manufacturing, advancing circular materials, and deepening industry partnerships. In South Asia, especially India, the company is expanding its R&D and technical service capabilities to co-develop products with local OEMs in automotive and electronics. In the Middle East and Africa, the focus is on entering high-growth markets through partnerships in countries with growing automotive and infrastructure sectors.

Envalior plans to offer region-specific grades of recycled and bio-based materials suited for high-heat and mechanically demanding environments. It also aims to expand collection and reuse networks for post-industrial waste, enabling closed-loop supply chains even in regions with developing recycling infrastructure. These steps are tied to helping customers meet new Extended Producer Responsibility (EPR) and carbon disclosure requirements. The company will continue to invest in low-emission logistics and renewable energy sourcing to meet its 2030 climate targets while growing responsibly in underserved regions.


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