ZF: Cutting-Edge Technologies & Solutions For India’s Trailer Industry

“With its extensive portfolio of cutting-edge technologies and innovative solutions, ZF is well equipped to meet the transformative trends and rapidly evolving market dynamics and become a driving force behind the ongoing growth and evolution of the Indian trailer sector.
V Ramanathan, Head – OE Business Commercial Vehicle Solutions Division, ZF Group

What is driving demand for trailers in the logistics industry?

With road transport comprising 71% of all logistics operations in the country, trucks and trailers have emerged as indispensable components of India's transportation and logistics infrastructure. India's burgeoning trailer industry has gained momentum, contributing substantially to the transportation sector. As transportation needs escalate, the demand for trailers has witnessed a surge.

However, in India, utilization of trailers is comparatively low at around 12% when compared to Europe or China. But we are seeing the landscape changing, thanks to the government's vision for infrastructure development and introduction of the National Logistics Policy. These initiatives are expected to significantly boost trailer penetration and usage, opening pathways for more efficient cargo movement through trailers.

What critical factors should be kept in mind during transportation by trailers?

The industry is continually working on innovative solutions to make trailer transportation safer, more efficient, and more environmentally friendly. In the current scenario characterized by limited trailer usage, several critical factors merit attention:

Safety: Ensuring the safety of both the cargo and other road users is paramount. Accidents, rollovers, or cargo shifting can lead to significant problems. However, accidents or mishaps while transporting cargo via trailers are sometimes unavoidable. Trailer tires are under significant stress, and a tire blowout can result in loss of control and an accident. Problems with the suspension or axles can lead to instability and handling issues. In addition, rollovers happen in the case of overloaded or improperly loaded trailers, especially during sharp turns or in adverse weather conditions.

Fuel Efficiency: Achieving optimal fuel efficiency while hauling heavy loads can be challenging. Efficient powertrains and aerodynamic designs are crucial to reducing fuel consumption.

Cargo Security: Preventing theft and damage to cargo during transport is a constant concern. Trailer security systems are important to address this. Environmental Regulations: Meeting emissions and environmental regulations, particularly in urban areas, can be challenging. Electric and hybrid trailer technologies are emerging solutions.

Infrastructure: The condition of roads, bridges, and infrastructure can affect trailer transportation. Poor infrastructure can lead to delays and increased maintenance costs.

Driver Shortage: A shortage of skilled truck drivers is a persistent issue in many regions. Attracting and retaining qualified drivers is crucial for the company.

Cargo Handling: Loading and unloading cargo efficiently and safely is important. This process can be time-consuming and labor-intensive.

Route Planning: This is a complex procedure, necessitating careful consi- deration of factors such as finding optimal routes, studying the road terrain, and being aware of potential obstacles like weight-restricted roads, steep gradients, overhead structures, among other factors.

Weight Limits: Regulations on trailer weight limits can vary by region. Ensuring compliance with these limits while maximizing cargo capacity is a balancing act.

Weather Conditions: Adverse weather conditions such as rain, snow, or high winds, can pose significant challenges to trailer transportation for which safety precautions and equipment must be in place to handle such situations.

Technology Integration: Implementing advanced technologies like autonomous driving, telematics, and connectivity in trailers requires significant investment and integration with existing systems.

Facilities at Destination Points: It is important to address the adequacy of loading and unloading facilities at destination points before commencing operations to prevent delays and disruptions.

Maintenance and Repairs: Ensuring the reliability of trailers through regular maintenance and addressing breakdowns promptly is essential for minimizing downtime.

Regulations: Adherence to the current regulations (Trailer Code) is critical to ensure compliance with safety norms and make trailers more efficient, thereby bringing down the Total Cost of Ownership

Trailer Utilization: Optimizing prime mover capacity is a key consideration to ensure that trailers are operating at their maximum potential, contributing to overall logistics efficiency.

What solutions does ZF offer to meet the above-mentioned challenges?

In a competitive, cost-conscious, and highly regulated transport world, every decision counts. The Intelligent Trailer Program (ITP) offered by ZF, brings efficiencies to the entire commercial vehicle industry — from trailer builders, fleets, shippers, and drivers — to daily operations.

Our goal is to deliver increased safety, efficiency, and connectivity. The Intelligent Trailer Program has more than 40 innovative trailer functions, for example, and it can make intelligent connections to the brake system, sensor technology, suspension, and chassis control.

As India's trailer industry is poised for expansion, addressing these critical factors will be pivotal in unlocking its full potential and facilitating smoother cargo transportation nationwide.

What are the advanced active safety systems, technologies and functionalities for improved trailer operations offered by ZF?

To ensure an integrated safety approach, it's essential that both the prime mover and the trailers are equipped with advanced active safety systems like ABS, Trailer ABS, or Trailer Electronic Braking Systems. ZF´s Trailer ABS is the industry’s first Anti-Lock Braking System for trailers. ZF has installed more than 9 million systems worldwide making it the world’s market-leading Trailer ABS.

ZF was also the first to introduce an Electronic Braking System to the global trailer market in 1997 and is now the global market leader for Trailer Electronic Braking Systems (TEBS) with more than 3 million units sold. T-EBS provides a comprehensive portfolio of safety and efficiency functions, for example it optimizes stopping distance and improves stability while braking, thereby maximizing safety.

Fleet owners are increasingly demanding additional safety features such as Autonomous Emergency Braking, ADAS (Advanced Driver Assistance Systems), and Driver Behavior Monitoring to further enhance the security of their operations. ZF’s portfolio of ADAS solutions include collision mitigation systems, autonomous emergency braking, Lane Departure Warnings, and driver behavior monitoring solutions.

Furthermore, tire monitoring is a critical factor in trailer safety, and this is being addressed through our Tire Pressure Monitoring System (TPMS). This system helps in real-time monitoring of tire pressure and temperature, ensuring that potential issues are detected and mitigated promptly, thus reducing the risk of tire-related accidents. The TPMS constantly monitors the performance of each tire and as soon as a problem is detected, the system alerts the driver to repair the tire. This helps in optimizing vehicle uptime, tire life, and fuel efficiency.

ZF’s Intelligent Trailer Program (ITP) offers more than 40 technologies/functionalities to assist daily trailer operations, improve safety, enhance trailer efficiency, and improve driver productivity. Introduced in 2018 for the Indian market, customers can select technologies based on their specific requirements. The ITP functions are classified into five key areas:

• Advanced Safety:
• Operational Efficiency:
• Load Optimization.
• Fuel & CO2 Reduction
• Driver Comfort & Effectiveness

Additionally, the introduction of connectivity solutions exclusively designed for trailers, such as the SCALAR Evo Pulse by ZF is revolutionizing the industry. These systems enable precise tracking of trailer movements, cargo weight monitoring (a crucial aspect in preventing theft), effective cargo loading, and overall safety enhancement. The adoption of Lift Axle Suspension systems is also gaining momentum as it increase fuel efficiency.

ZF's innovative solutions are raising the bar for performance, efficiency, and safety, and they can only do this by utilizing the possibilities of whole truck-trailer combinations. Our extensive portfolio of cutting-edge technologies and innovative solutions for is poised to be a game-changer for the Indian trailer industry. In an era marked by transformative trends and rapidly evolving market dynamics, ZF emerges as a strategic partner, equipping the industry to not only keep pace with change but to thrive within it. With a keen understanding of the unique demands of the Indian market, our offerings are tailored to enhance the performance, efficiency, and safety of trailers, ultimately elevating the entire industry.

How do OEMs collaborate with component manufacturers like ZF?

OEMs often provide guidelines and recommendations for routine maintenance and inspection schedules. ZF’s connectivity solutions can offer predictive updates to fleet owners and drivers alerting them of maintenance updates.

OEMs’ technical support teams provide guidance to trailer owners and operators in case of issues. Support can include remote troubleshooting and diagnostics to identify problems quickly. ZF CVS India’s pan-India service network ensures round-the-clock support for fleets.

OEMs have started incorporating connected solutions to enable smarter and more efficient fleet and driver monitoring systems for trailer fleets. ZF is a preferred solution provider to leading trailer OEMs for trailer connectivity solutions. The systems allow real-time tracking of trailer conditions and performance, enabling early detection of issues and remote troubleshooting.

Data analytics and predictive maintenance algorithms are gaining ground as they help to anticipate and prevent potential issues. By analyzing data from sensors and telematics systems, they can schedule maintenance before a breakdown occurs. ZF’s capabilities include big data analytics and predictive maintenance.

ZF's comprehensive solutions, including Trailer EBS, Intelligent Trailer Program, OptiTire™, SCALAR Evo Pulse, Reverse Parking Assist System, and Tail Guard, among others, are poised to propel the Indian trailer industry forward, enabling it to embrace these transformative trends and meet the demands of an evolving market.

Please share a recent case study highlighting the challenges while executing a project.

In a recent case study within the Indian trailer industry, a fleet owner embarked on a journey to optimize trailer efficiency and maximize tractor utilization. In the prevailing landscape, each trailer was traditionally coupled to a single tractor, resulting in a starkly underutilized tractor fleet, with an efficiency rate as low as 20%.

Recognizing this inefficiency, the fleet owner made a strategic move by opting for individual trailer registration. This transformative decision allowed a single prime mover to efficiently manage multiple trailers, leading to an impressive 80% improvement in tractor utilization.

Such an innovative approach not only enhances operational efficiency but also serves as a noteworthy example of how progressive strategies are reshaping the dynamics of the Indian trailer industry.

What are the areas of concern while acquiring heavy haul trailers?

Acquiring heavy haul trailers is a significant investment, and there are several important concerns that require making informed decisions and ensuring that the trailers meet their specific needs.

Payload Capacity & Choosing Trailer Type: Assessing the payload capacity of the trailer to ensure it can handle the weight and size of the cargo to transport. Consider both legal weight limits and any oversized or overweight permits needed. Choosing the appropriate trailer type for specific haulage requirements is essential, as each type is designed for different types of cargo.

Regulatory Compliance: Ensure that the trailer complies with all local, state, and federal regulations, including safety, size, weight, and equipment requirements.

Axle Configuration: Consider the number and configuration of axles on the trailer to distribute the weight properly and meet legal weight limits. Some trailers may have axles that can be adjusted to accommodate different loads.

Suspension System: It is important to choose a suspension system suitable for cargo and intended use as it can significantly impact ride quality and load stability. The air suspension is preferable considering the current axle load norms.

Braking System: Ensure that the trailer is equipped with a reliable and efficient braking system to meet safety standards and provide adequate stopping power for heavy loads. The trailer should be fitted with Trailer ABS (in compliance with Trailer Code) or Trailer EBS (T-EBS) for enhanced safety.

Safety Features: Reflective markings, lighting systems, and warning signs enhance visibility and safety during transport. ZF’s Intelligent Trailer Program for safety makes trailer driving situations such as cornering, braking, reversing, or delivering safer and easier for the driver. This suite of trailer functions helps to reduce damage as well as repair costs and increases uptime.

Licensing and permits: Understand the licensing and permit requirements for operating heavy haul trailers in your region. This may include special licenses or permits for oversized or overweight loads.

Maintenance and Serviceability: Consider the ease of maintenance and availability of service and repair facilities for the trailer. Regular maintenance is essential to ensure reliability and safety.

Cost of Ownership: Calculating the total cost of ownership, including the purchase price, insurance, maintenance, fuel, and any financing costs. Ensure the investment aligns with your budget.

How do you see India’s trailer market changing and evolving?

The Indian trailer industry, though displaying remarkable dynamism, has long harbored untapped potential awaiting exploration. The presence of low entry barriers, high fragmentation, and a dearth of government regulations has historically contributed to its largely unorganized state.

However, the scenario is gradually evolving with the entry of established players and the introduction of government regulations. Presently, the Indian trailer market is dominated by domestic players, with a limited presence of international counterparts, primarily in niche segments like hazardous cargo carriers.

Unlike international markets, where large multinational corporations often maintain mega fleets, Indian MNCs tend to outsource their logistics and transportation requirements to multiple entities. Nevertheless, the industry is now experiencing a significant shift in focus. With the emergence of global fleets, increasing awareness, stringent regulations, and a growing emphasis on sustainable mobility, cargo security, and driver comfort, the Indian trailer industry is actively striving to enhance safety, efficiency, and alignment with global benchmarks. In fact, it is evident that the trailer sector is undergoing a significant transformation, with safety, efficiency, and advanced technologies playing pivotal roles in shaping its future.

To bring the trailer industry at par with global standards, the Government of India has introduced various regulations related to safety, emissions standards, and weight restrictions. These regulations are aimed at streamlining and formalizing the Indian trailer market.

The Ministry of Road and Transport and Highways (MoRTH) has mandated trailer standards Central Motor Vehicles Rules (CMVR) 125D, which have been in effect since 2017. It requires standardization in trailer body, braking systems, and ABS installation to make it safer. However, only 20% of trailers in India are compliant with the mandated standards. This requires a stronger emphasis on bringing the regulations into practice.

How do you envisage the demand of trailers in the growing Logistics market of India?

The logistics landscape in India is on an upward trajectory, poised to grow at a remarkable CAGR of 6.46% from 2023 to 2029, ultimately reaching a substantial value of USD 279.04 billion by 2029. This sector holds tremendous significance, contributing a robust 3.6% to India's GDP. Within this landscape, the road transport industry plays a pivotal role in alignment with the burgeoning demand for trailers in India's expanding logistics market.

With approximately 71% of India's cargo movement relying heavily on road transportation, this segment assumes paramount importance. Government initiatives such as the National Logistics Policy, aimed at reducing logistics costs from 18% to 8%, are poised to further propel the demand for trailers. This demand is fueled by the inherent efficiency they bring to the logistics chain, especially as India continues to invest in infrastructure development, including the expansion of express highways. This confluence of factors is set to significantly enhance trailer penetration in the Indian market, making it an exciting and dynamic sector.

What support is required from the government in terms of policies and infrastructure for smooth ODC transportation?

Over-dimensional cargo transportation (ODC) presents challenges, including legal and regulatory issues, infrastructure limitations, and specialized handling requirements. The government can play a major role in supporting ODC transportation by providing clear and consistent policies, making infrastructure improvements, and funding research and development.

There is a pressing need for the government to reconsider and potentially increase the allowable Gross Vehicle Weight (GVW) for trailers based on the number of axles they possess. The current restriction to a maximum of 55 tons irrespective of the number of axles is limiting the industry's potential for efficiency and safety improvements.

It is imperative that the government incentivizes trailer registration. Such incentives can encourage compliance, improve accountability, and contribute to enhanced road safety.

The promotion of electronically controlled air suspension systems is paramount. These systems have the potential to optimize road load distribution, significantly reducing road maintenance costs and minimizing wear and tear on our already strained road infrastructure.

Despite the Trailer Code regulation in place for Trailer Anti-lock Braking Systems (ABS), their penetration remains at a mere 22%. Government initiatives and incentives should be put in place to encourage the adoption of Trailer ABS (TABS) to improve overall road safety.

A crucial aspect often overlooked is the focus on driver comfort and wellness. Recognizing the importance of the human element in transportation, efforts should be made to enhance the working conditions and well-being of trailer drivers. This includes provisions for rest areas, proper facilities, and initiatives promoting their overall health and job satisfaction. These combined efforts can drive positive change within the Indian trailer industry, ensuring both safety and efficiency in our transportation infrastructure.

What initiatives are you taking to reduce carbon emissions in the transport sector?

In the rapidly evolving landscape of the Indian trailer industry, we witness a significant shift as Original Equipment Manufacturers (OEMs) and trailer fleets are becoming increasingly focused on reducing emissions and carbon footprint, improving trailer efficiency, and lowering the Total Cost of Ownership.

Globally there is a gradual transition to new energy vehicles, including Battery Electric Vehicles (BEV), Fuel Cell Electric Vehicles (FCEV), and Hydrogen Internal Combustion Engine (H2-ICE) technology. We are taking significant steps to reduce carbon emissions in the transport sector through the Intelligent Trailer Program. This program offers a range of innovative functions that increase efficiency, safety, and driver comfort. The main functions include OptiTire, OptiFlow, Fuel Saving Suspension, and Lift Axle Control. OptiTire helps to avoid under-inflation, which can lead to increased fuel consumption and CO2 emissions. It also helps to prevent tire blowouts, which can improve safety and vehicle uptime and can enable fuel savings of up to 2% and a reasonable reduction of CO2 emissions.

Secondly, OptiFlow improves trailer aerodynamics to save fuel and reduce CO2 emissions. It does this by using lightweight composite components to minimize drag and reduce air friction. OptiFlow Tail can enable fuel savings of up to 1.1 l / 100km at highway speeds and helps to deliver annual CO2-emission savings of up to 2.8 t per trailer. OptiFlow SideWings provides fuel savings of up to 1.5 l / 100 km at highway speeds and enable annual CO2-emission savings of up to 3.8 t per trailer.

Fuel-saving suspension helps to optimize trailer height while driving to improve stability and fuel economy. It does this by automatically controlling chassis height while driving, only using air from the compressor if necessary. The Fuel Saving Suspension can help to save up to 150 liters of fuel and to reduce up to 407 kg of CO2 emissions per truck per year compared to conventional air suspension.

The lift axle control automatically lifts the lift axle of an empty trailer, optimizing operational efficiency and reducing CO2 emissions and fuel consumption. It also helps to reduce tire wear and rolling resistance on lifted axles while maintaining stability.

One of our standout innovations is the patented E-Trailer technology, which offers fuel savings, and CO2 emission reductions and is sustainable. Ours electrified trailer portfolio is a complete electrified trailer solution that holistically integrates the management of truck and trailer brakes, stability, and e-traction. The electrified trailer turns truck-trailer combinations into hybrids. ZF’s electrified trailer potentially contributes fuel and CO2 savings of up to 16% on short-haul routes, and up to 7% for long-haul applications in a truck-trailer combination. We are committed to driving these advancements in trailer technology, underscoring our dedication to sustainable, efficient, and forward-thinking solutions for the Indian transportation sector.

What future trends and innovations in ODC transportation do you foresee?

The use of technology, such as the Internet of Things (IoT) and tracking systems, is becoming increasingly common in ODC transportation. This allows logistics providers to track and monitor cargo in real-time, which can help them to optimize routes, detect potential problems, and ensure timely delivery.

Even automation and robotics are playing a growing role in ODC transportation. Automated cranes, self-loading trailers, and robotic lifting mechanisms can help to improve operational efficiency, reduce human error, and enhance safety. Sustainable practices are becoming increasingly important in the transportation industry, and ODC transportation is no exception.

Logistics providers are exploring ways to minimize the environmental impact of ODC transportation, such as using electric or hybrid vehicles and sustainable packaging materials. As the industry continues to evolve, we can expect to see even more innovative ways to move ODC transportation more safely and efficiently.