Mahle Diversifies to Offset Trend to Smaller Engines

Switching to engines with fewer cylinders can help carmakers meet fuel economy goals. But it's not a welcome trend for a parts suppliers like Mahle Group, which controls 30% of the global market for automotive pistons.

That's why the Stuttgart, Germany-based company is pushing to diversify its components business. Mahle says it is increasingly focused on expanding its portfolio of high-tech solutions to boost fuel efficiency.

In North America, Mahle is consolidating operations at five locations in metro Detroit at its expanding engineering center in Farmington, Mich. It also is increasing its work on ignition and turbocharging systems, says Scott Ferriman, vice president of sales and application engineering at the Farmington complex.

For example, the company is developing a new ignition system for lean-burn combustion. Ferriman says the technology can be retrofitted to existing engine designs and has the potential to increase fuel efficiency by about 20%.

Mahle also is working with Robert Bosch GmbH to develop turbochargers for downsized engines. Separately, Mahle and Behr GmbH have developed an innovative indirect charge-air cooler for turbocharged engines that integrates an intercooler into the intake manifold.

Mahle, which has acquired nearly 37% of Behr since 2010, aims to take a majority stake in the thermal systems supplier next year. The plan has been stalled since summer, when the European Commission launched an antitrust analysis.

Ferriman notes that Mahle is demonstrating some of its new components in a 1.2-liter, three-cylinder prototype engine that is fitted with the Behr/Mahle intercooler, Bosch/Mahle turbocharger and ultra-lightweight pistons. The engine develops about 190 hp and 40 mpg in a C-class sedan, according to the company.