I remember having this conversation with my dad about fuel prices, where he mentioned, “In those days, filling your tank for Rs 1000 was a huge deal. Today, the majority of the population has accepted their fate and filled their fuel while emptying their pockets every day.
One of the booming alternatives is an Electric Vehicle (EV), but people have their concerns. But what if there was a way to retain your old vehicle yet not use petrol as its fuel?
Sivasankari TP, the founder of AR4 Tech, can make it happen! With a retrofitting solution that converts conventional petrol and diesel vehicles into electric ones for just Rs 39,900, she is revolutionising the landscape of electric mobility, particularly in India’s Tier 3 and Tier 4 cities.
The journey of hardships
From a remote village, Thakkolam, in Kanchipuram, where girls’ education was often discouraged, a remarkable journey began. “My village does not support women’s pursuit of education. But my dad fought with them to provide quality education, making me and my sister the first female graduates from the family,” shares Sivasankari, who has an MTech in information technology.
This early support laid the foundation for a diverse career path, starting as a lecturer before family life led her to explore entrepreneurship. From selling silk sarees to running a successful herbal hair treatment business, she has demonstrated remarkable adaptability. COVID-19 forced the closure of her ventures, but it also opened a new door.
Migrating to Coimbatore in late 2019, Sivasankari took on the role of Operations Manager at EMF Innovations, a motor manufacturer for electric two-wheelers. “I am good at setting up a business, hiring and retaining employees,” she says, highlighting her strengths. Despite lacking technical expertise, her skills in team building and business acumen proved invaluable, especially during the challenging times of the pandemic.
“Since I was a lecturer, I knew the potential of the last benchers, and I had employed them,” she adds, revealing her unique approach to talent acquisition. EMF flourished under her leadership, eventually attracting interest from numerous companies, culminating in a merger with Sriram Pistons and Rings.
After a brief stint as a partner, she embarked on a new venture, AR4 Tech, where she serves as Managing Director. “AR4 tech started as a challenge,” she explains. Leveraging her experience from EMF, where they had pioneered motor design for Indian roads, she and her colleague, Mahesh Pandey, set out to convert existing vehicles to electric power.
“We were the pioneers to manufacture our motor in India and use it in conversion,” she states proudly. With investment from her mentor, Professor CC Hong, AR4 Tech was poised to revolutionise sustainable transportation. Drawing from her experience at EMF and driven by her entrepreneurial spirit, she recognised a critical gap in the Indian EV market: affordability. This realisation, coupled with her drive to make a difference, led to the founding of AR4 Tech.
Affordable & quick EV conversions
AR4 Tech, aptly named for ‘Automotive Repair, Refurbish, Repurpose, and Recycle,’ embodies its acronym. Their core business lies in converting internal combustion engine (ICE) two-wheelers into electric vehicles (EVs).
“We primarily convert normal two-wheeler IC vehicles into EVs in under two hours for Rs 39,900,” explains Sivasankari. With approvals secured for popular models like the Honda Activa and TVS Zest, their simplified kit is designed for widespread adoption, particularly amongst women.
“The automobile industry is challenging for women, but I didn’t want EVs to be similar to that,” she states. The ‘no-weld, no-grind, no-cut, and no-drill’ approach streamlines the conversion process, a feat achieved through significant R&D investment. “We have modified it to provide a battery pack. We have no fabrication activity. We just need to remove the IC engine and replace the battery kit using a plug-and-play method,” she explains.
AR4 Tech’s focus on localisation sets them apart. “We have localised all four components, and no importing is involved,” she emphasises. From self-designed and procured motors to their own sodium-ion battery pack management plant — a first in Tamil Nadu — they control the entire process. Currently, they offer conversions with a 50km range and 40km/h speed, backed by a three-year warranty on the motor and battery and one year on the controller.
Beyond two-wheelers, AR4 Tech also converts older Tata Dost vehicles into electric golf carts for in-campus use. “We have used composite, which has helped to remove 170 kg of weight from the vehicle,” she notes, showcasing their focus on efficiency. Adding solar panels and using sodium-ion batteries further enhances the sustainability of these conversions. “Customisation has been the power of AR4 Tech,” she asserts, highlighting their ability to meet diverse needs.
Finding a place in tier 3 and 4 cities
While most EV companies target urban markets, AR4 Tech has carved a unique niche by focusing on Tier 3 and 4 cities. With 95% of its two-wheeler sales originating from these communities and selling 800 vehicles across categories post-ARAI approval, AR4 Tech demonstrates a deep understanding of and connection with populations outside major metropolitan areas.
AR4 Tech’s hands-on marketing strategy further reinforces this commitment. “A dedicated team travels weekly to towns like Pollachi, Karur, and Tiruppur, identifying local social media influencers and securing permission to hold vehicle demonstrations at schools, colleges, or public gathering spots,” Sivasankari recalls. Promoting these events with notices and banners, they showcase their EV conversions and engage directly with potential customers.
These demonstrations typically generate three types of inquiries: individual conversions, requests for skilling opportunities, and interest in dealerships. AR4 Tech caters to all three, offering a comprehensive approach that expands its reach and empowers these communities to embrace sustainable transportation.
“Since we are providing it in swapping, they can easily charge using a 15-amp socket,” adds Sivasankari, simplifying the process of charging as well. “The vehicle gets fully charged in three hours, and I can travel around 80 km per day, which is sufficient for my daily commute,” shares Sudarshan Chandrasekaran, a finance manager from Coimbatore.
The big question — Will it blast?
“Initially, we used lead-acid batteries, which were bulky and required regular maintenance with distilled water,” she explains. “The next generation was lithium, which encompasses various chemistries, the most successful being NMC (Nickel Manganese Cobalt) and LFP (Lithium Iron Phosphate).”
However, she expresses concern about the safety of NMC batteries in India’s climate. “Cobalt is a reactive material which makes it easy to blast,” she warns, noting the high temperatures during Indian summers.
She points out the discrepancy between European guidelines, on which Indian policies are based, and India’s unique climatic conditions. While acknowledging that LFP batteries can also pose a fire risk, she emphasises their relative safety compared to NMC.
“At AR4 Tech we only used LFP and Sodium,” she states. “We are against NMC batteries to be used in India.” This commitment to safer battery chemistries means that AR4 Tech’s converted EVs are designed with safety in mind, significantly reducing the risk of fires or explosions.
Challenges and training programmes
Navigating the regulatory landscape has been a significant hurdle. “It was hectic to get ARAI (Automotive Research Association of India) and state transport approval,” she recalls. While ARAI approval signifies adherence to safety standards, state governments often have differing requirements, leading to further complications.
The recurring validation process and fluctuating GST percentages, now classified as second-hand vehicles, add to the challenges. “We have written letters for the same. Hopefully, things will change,” Sivasankari adds, advocating for more supportive policies for the EV sector.
Despite a non-technical background, she has embraced the learning curve. “I struggle when technical questions come my way, but my team members have been of great help,” she admits.
Building a skilled team for the relatively new field of retrofitting presented its own set of challenges. “Nobody knew which part had to be used and which had to be discarded,” she explains. Hiring locally and providing training have been key to their success. “25% of the employees here are women,” she notes proudly, many of whom have gained valuable skills through the company’s support, including pursuing ITI degrees.
“It was a little difficult to dismantle the two-wheeler in the beginning. But now I can do it with ease,” shares Thanga Mani, a two-wheeler technician at AR4 Tech. She must have been involved in the conversion of over 100 two-wheelers in the past years.
Recognising the potential for job displacement with the rise of EVs, AR4 Tech is committed to skilling and training. “We have also provided training programmes and skilling for all the conversions that we do,” she says.
These programmes, ranging from short courses to three-month diplomas certified by the Automotive Skill Development Corporation and the World Skill Council, empower individuals with the skills needed for the evolving automotive landscape. “To date, we have provided skilling to over 200 people,” she adds.
This commitment to both innovation and community development has translated into substantial growth, with revenue projected to more than double this financial year. “Last year, we made a revenue of Rs 1.67 crores; we are hoping to close this year by Rs 4 crores,” shares Sivasankari.
Driving India towards sustainability
AR4 Tech’s ambitions extend beyond conversions. “We are planning to start a unit for academic activity,” she reveals, encompassing a one-year design course to empower aspiring entrepreneurs and service technician training to boost community support.
“We want to start sodium battery pack manufacturing, designing and skilling as well,” Sivasankari adds, outlining their commitment to developing and disseminating this promising technology. Exploring hydrogen and drone technology is also on the agenda, alongside the design of their vehicles. This forward-thinking approach is evident in their current projects.
“We are also planning to convert tractors to EVs,” she explains, highlighting their innovative approach to repurposing existing vehicles. Plans to convert buses and trucks are also on the horizon.
The founder’s vision is clear: “Sustainability should not be a privilege. It should be accessible to everyone.” Through AR4 Tech, she is making that vision a reality. As fuel prices continue to fluctuate and environmental concerns escalate, AR4 Tech’s innovative model offers a practical, cost-effective alternative. With a passionate leader at the helm and a solution that genuinely benefits the masses, this startup is well on its way to reshaping India’s transportation landscape.
The question now is not whether EVs are the future, but rather, how soon can we make the switch?
Visit their website to learn more about EV conversions.
Edited by Megha Chowdhury; All images courtesy AR4 Tech
