kalyani powertrain apsrtc diesel bus electric ac coach retrofit

Kalyani Powertrain and APSRTC Successfully Retrofit 14-Lakh-KM Diesel Bus into Electric "Super Luxury" AC Coach In a major milestone for circular engineering in the Indian automotive market, Kalyani Powertrain Limited—the electric mobility arm of Bharat Forge—has successfully completed the conversion of an aging diesel-powered state transport bus into a fully electric, air-conditioned "Super Luxury" coach. Done in partnership with the Andhra Pradesh State Road Transport Corporation (APSRTC), the project serves as a key proof-of-concept (PoC) evaluating vehicle retrofitting as a scalable alternative to total fleet scrap-and-replace strategies. The Transformation Profile The vehicle selected for the conversion was an inner-city workhorse belonging to the Mangalam RTC depot in the Tirupati district. Originally commissioned in 2017, the donor diesel bus had logged an extensive 14.54 lakh kilometers of operation. Instead of routing the vehicle to a scrapping yard, engineers at the Vidhyadharapuram RTC workshop executed a thorough clean-sheet mechanical overhaul starting in late December 2025. The conventional internal combustion engine (ICE), diesel fuel tanks, transmission lines, and the structural body shell were entirely stripped from the chassis. [Diagram of ICE-to-EV retrofitting process for heavy commercial vehicles] Technical Architecture & Component Breakdown The conversion process successfully merged Kalyani Powertrain's proprietary high-voltage electronic architecture with components engineered for heavy-duty commercial cycles: Powertrain Integration: A modular electric powertrain kit and automated vehicle control unit (VCU) replaced the traditional mechanical transmission layout. Battery System: A specialized high-capacity battery kit valued at approximately ₹58.5 lakh was integrated onto the chassis, specifically insulated and mounted to safely withstand high ambient operating temperatures. Charging Capabilities: The vehicle supports high-output opportunity charging through an outsourced 240 kW DC fast-charger (costing ₹11.5 lakh), enabling the bus to replenish from a 20% state-of-charge to 100% in approximately 120 minutes. Body Restructuring: A completely new premium air-conditioned bus body was built by Amba Coach Builders for ₹25 lakh to finish the premium configuration. Operational Fleet Metrics Initial metrics released indicate that the retrofitted electric coach delivers a reliable on-road driving range of 210 to 230 kilometers per charge. Following pre-commissioning testing in Vijayawada, the coach is headed to the Central Institute of Road Transport (CIRT) in Pune for formal homologation. Once green registration plates are cleared, APSRTC intends to deploy the bus on high-traffic commercial trial routes between Nellore and Tirupati, utilizing existing charging infrastructure in both transit hubs. Economic Viability and Market Outlook State Transport Undertakings (STUs) across India are facing immense pressure to transition to zero-emission fleets while simultaneously managing strict capital expenditure limits. For operators, a brand-new electric 12-meter bus can cost upwards of ₹1.5 crore. In contrast, the component cost structure of this retrofitting pilot demonstrates that an existing, paid-off asset can be extended for a second life at a fraction of that investment. The success of this pilot underpins Kalyani Powertrain’s broader commercial strategy. The company is steadily capturing early market share in the heavy fleet repowering segment, having already secured a commercial order from the neighboring Telangana State Road Transport Corporation (TGSRTC) to convert 40 older diesel buses to electric drive systems. As India’s National Electric Bus Programme gains momentum, localized retrofitting technologies are proving that the fastest route to a green transition might be rebuilding the assets the country already owns.