Montra Electric’s Bicycle Roots Power EV Transformation

How a Bicycle Legacy Ignited Montra Electric’s EV Journey

What began as a modest idea rooted in bicycles has quietly grown into a full-fledged electric mobility movement at Montra Electric, part of the Murugappa Group. Around five years ago, the company began rethinking mobility through the same lens that once defined its earliest product — simplicity, accessibility, and sustainability. Today, that thinking has materialised at Ambattur in Chennai, where a legacy bicycle plant has been transformed into a modern electric vehicle manufacturing hub.

The Ambattur facility represents a rare bridge between eras. It carries forward decades of engineering discipline while embracing electrification, digital systems, and sustainable manufacturing. Once synonymous with cycle production, the plant has now been rebuilt to support electric three-wheelers, marking one of the group’s most significant industrial transitions.

At the heart of this shift is Montra Electric’s expanding portfolio of passenger and cargo electric three-wheelers. The Super Auto, with a real-world range of 160 kilometres, has already crossed more than 13,000 units on the road, collectively covering close to 150 million kilometres. The Super Cargo range pushes boundaries further, offering up to 170 kilometres of range with a 13.8 kWh battery and a fast-charging time of just 15 minutes. For heavier commercial needs, the Super Capacity Cargo delivers a 1.2-tonne payload across multiple body configurations, widening its appeal among urban and regional operators. Sales have scaled steadily, supported by 150 showrooms across 114 markets, with strong demand from eastern and northeastern India.

The transformation of Ambattur gathered pace around 2020, when bicycle manufacturing was largely shifted to Punjab. Since then, the Chennai cluster has emerged as a multi-EV ecosystem, housing electric three-wheelers in Ambattur, electric tractors nearby, small commercial EVs in Ponneri, and heavy-duty EV operations in the NCR region. Ambattur itself is geared entirely towards E3W production, spread across 12 acres with painting, assembly, finishing, and end-of-line testing under one roof.

Montra Electric’s journey is underpinned by strong in-house engineering. A dedicated technology centre laid the groundwork for powertrain and battery validation, supported by a 120-member design team, quality specialists, and advanced testing infrastructure. Digital tools now guide every stage of assembly, from torque-controlled fastening to QR-based battery tracking, ensuring traceability and consistency.

Manufacturing blends craftsmanship with automation. Robotic painting systems apply corrosion-resistant coatings, while digitally monitored conveyors synchronise each production step. A tightly localised supply chain further enhances efficiency, with nearly 80 percent of suppliers located close to the plant.

Sustainability runs deep across operations. Around 90 percent of energy comes from green sources, with solar capacity expanding further. Water recycling, zero discharge systems, and lean inventory practices reinforce the plant’s low environmental footprint.

From bicycles to electric vehicles, Ambattur’s evolution reflects how legacy manufacturing can adapt to future mobility — proving that innovation, when rooted in purpose, can redefine an entire ecosystem.