E-Rickshaw Manufacturing Plant

Report Overview:

IMARC Group’s report, titled “E-Rickshaw Manufacturing Plant Project Report 2025: Industry Trends, Plant Setup, Machinery, Raw Materials, Investment Opportunities, Cost and Revenue,” provides a complete roadmap for setting up a e-rickshaw manufacturing plant. It covers a comprehensive market overview to micro-level information such as unit operations involved, raw material requirements, utility requirements, infrastructure requirements, machinery and technology requirements, manpower requirements, packaging requirements, transportation requirements, etc. The e-rickshaw manufacturing plant project report provides detailed insights into project economics, including capital investments, project funding, operating expenses, income and expenditure projections, fixed costs vs. variable costs, direct and indirect costs, expected ROI and net present value (NPV), profit and loss account, financial analysis, etc.

What is E-Rickshaw?

An e-rickshaw is an electric three-wheeler used for short-distance passenger or goods transport. It runs on an electric motor (usually 650–1500W) driven by lead-acid or lithium-ion batteries. E-rickshaws have zero tailpipe emissions, making them an energy-efficient and environmentally friendly mode of transport compared to conventional fossil-fuel-based auto-rickshaws in urban and semi-urban spaces.

E-Rickshaw Manufacturing Plant: Key Highlights

• End-use Industries: Passenger transport, school transport services, feeder services, tourist transport and cargo transport
• Applications: Used in short-distance, low-speed transportation, primarily for passenger mobility and light goods delivery

An e-rickshaw manufacturing plant is a facility used to assemble and manufacture electric three-wheelers intended for green transportation. The plant usually has the main elements of chassis fabrication units, motor and battery assembly lines, body panel production, paint booths, and quality checking areas. The plant incorporates electric drive technologies, typically BLDC motors and lead-acid or lithium-ion batteries, into robust vehicle frames for city and semi-city driving. Sophisticated testing and security procedures are followed to meet regulatory requirements for performance, battery safety, and emissions. These plants respond to increasing demand for passenger mobility and light goods transport segments, particularly in nations advocating cleaner and affordable mobility solutions.

E-Rickshaw Industry Outlook 2025:

The expansion of the e-rickshaw market is increasingly driven by a mix of economic, environmental, and regulatory factors. The most significant factor is the increasing need for cost-effective and environment-friendly last-mile transportation solutions in highly populated urban and semi-urban regions of developing nations, such as India. E-rickshaws provide an affordable alternative to traditional auto-rickshaws due to their low running and maintenance expenses, mainly as they are powered by electricity, not petrol or diesel. This has led to widespread adoption among low-income drivers and small entrepreneurs. Government initiatives and policies also contribute to this direction. For instance, India's FAME-II program (Faster Adoption and Manufacturing of Hybrid and Electric Vehicles) and state-level subsidies have made the e-rickshaw more accessible by lowering initial expenses and encouraging manufacturers to produce larger quantities. Also, increasing environmental pressures and the advocacy for clean energy substitutes have turned the e-rickshaw into a preferred option for cities looking to end vehicular emissions. E-rickshaws play a big role in carbon footprint minimization and urban air quality enhancement. Advances in battery technology, particularly the move from lead-acid to lithium-ion batteries, have improved the endurance, range, and safety of e-rickshaws, making them more attractive to end-users. Growth in charging infrastructure and battery swapping stations in cities is further reducing range anxiety and facilitating increased adoption. With fuel prices remaining uncertain, the popularity of electric mobility solutions such as e-rickshaws is likely to increase, making them a foundation of the transportation ecosystem in future cities.

E-Rickshaw Market Trends and Growth Drivers:

Government Incentives and Electric Mobility Push

Government incentives and the drive for electric mobility are among the most important trends driving the e-rickshaw market growth. Programs like India's Economic Times- FAME II (Faster Adoption and Manufacturing of Hybrid and Electric Vehicles) scheme have offered monetary incentives to electric vehicle manufacturers and buyers, including e-rickshaws. In September 2024, the PM e-Drive scheme introduced by the Indian government provides additional subsidies exclusively for e-rickshaws to encourage lower-income earners and small-scale transport business operators to adopt their use. The program currently supports 1,10,596 e-rickshaws and e-carts. In addition, some state government policies include further incentives, such as exemptions from road tax, free registration, and low-interest rate loans, making e-rickshaws both financially sustainable and affordable to many people. Such initiatives have boosted both supply and demand, with indigenous manufacturers quickly ramping up their production.

Last-Mile Connectivity and Urban Transport Needs

E-rickshaws have become an important part of last-mile connectivity in densely populated urban and semi-urban spaces. As the trend of urbanization increases and there is a growing requirement for cost-efficient, short-distance transportation, e-rickshaws have become inevitable in offering cost-efficient mobility solutions. According to the International Energy Agency (IEA) report, sales of electric three-wheelers increased by almost 20% to reach approximately 700,000 units in 2024, maintaining India's position as the world's largest market for these vehicles for the second consecutive year. Due to low maintenance and fuel expenses, as well as their ability to move through crowded city roads, they are a favorite among passengers and drivers alike. With increasing usage, the demand for e-rickshaws has prompted these companies to expand their dealer networks and offer a range of models suitable for both cargo and passenger services. Such convenience and affordability have not only turned e-rickshaws into a lifeline for micro-entrepreneurs but also made them an essential component of India's evolving urban mobility ecosystem.

Technological Advancements and Battery Innovation

Another trend in the e-rickshaw industry is the technological transformation towards more efficient battery packs. Initially dominated by lead-acid batteries, the market is now experiencing a growing preference for lithium-ion batteries due to their lighter weight, quicker charging, and longer durability. This has dramatically enhanced the performance and range of operation of e-rickshaws, attracting more end-users. Most of these manufacturers are also adding smart features like GPS tracking, digital fare meters, and battery management systems (BMS), improving the overall consumer experience. Concurrently, investments in localized battery production and second-life battery applications are on the rise, supporting circular economy principles and decreasing dependency on imports. These innovations in technology are not only enhancing product quality and durability but also decreasing the TCO for drivers.

Latest Industry Developments:

• February 2025: Bajaj Auto plans to join the domestic e-rickshaw market by the end of the fiscal year to take advantage of a sizable and expanding industry. Aiming to penetrate a fragmented and import-dependent market that sells about 45,000 units each month, the company's new e-rickshaw is anticipated to set a new benchmark.
• December 2024: Zelio Ebikes has introduced the Tanga Butterfly and Tanga SS e-rickshaw versions in India. With their remarkable specifications, they serve commuters who live in urban and semi-urban areas.
• September 2024: The 'Mayuri' brand owned by Saera Electric Auto Ltd., which has set a lofty goal to sell 50,000 e-rickshaws by the end of the fiscal year, up from more than 33,000 units in the previous one. In order to do this, the business is growing its dealer network throughout India with the goal of gaining 10% of the market, which is a significant rise from its 6% share in FY 23–24.

Leading E-Rickshaw Manufacturers:

Leading manufacturers in the global e-rickshaw industry include several multinational companies with extensive production capacities and diverse application portfolios. Key players include

• Charuvikram Automobiles Pvt. Ltd.
• A G International Pvt. Ltd.
• Saera Electric Auto Pvt. Ltd.
• Gauri Auto India Pvt. Ltd.
• Yuva E Rickshaw
• Xuzhou Hongsengmeng Group Co., Ltd.
• Wuxi Weiyun Motor Co. Ltd.
• Wuxi Berang International Trading Co., Ltd.
• Udaan E Rickshaw

all of which operate large-scale facilities and serve end-use sectors such as passenger transport, school transport services, feeder services, tourist transport and cargo transport.

E-Rickshaw Plant Setup Requirements

Detailed Process Flow:

The manufacturing process is a multi-step operation that involves several unit operations, material handling, and quality checks. Below are the main stages involved in the e-rickshaw manufacturing process flow:

• Unit Operations Involved
• Mass Balance and Raw Material Requirements
• Quality Assurance Criteria
• Technical Tests

Key Considerations for Establishing an E-Rickshaw Manufacturing Plant:

Setting up an e-rickshaw manufacturing plant requires evaluating several key factors, including technological requirements and quality assurance. Some of the critical considerations include:

• Site Selection: The location must offer easy access to key raw materials such as metal body structure, battery, electric motor, axles and suspension, tyres, plastic and fiber parts, brake and steering systems and glass and uphosltery. Proximity to target markets will help minimize distribution costs. The site must have robust infrastructure, including reliable transportation, utilities, and waste management systems. Compliance with local zoning laws and environmental regulations must also be ensured.​
• Plant Layout Optimization: The layout should be optimized to enhance workflow efficiency, safety, and minimize material handling. Separate areas for raw material storage, production, quality control, and finished goods storage must be designated. Space for future expansion should be incorporated to accommodate business growth.​
• Equipment Selection: High-quality, corrosion-resistant machinery tailored for e-rickshaw production must be selected. Essential equipment includes metal fabrication equipment, painting and coating machines, electrical assembly tools, plastic injection molding machines, vehicle assembly lines, testing equipment and miscellaneous tools. All machinery must comply with industry standards for safety, efficiency, and reliability.​
• Raw Material Sourcing: Reliable suppliers must be secured for raw materials like metal body structure, battery, electric motor, axles and suspension, tyres, plastic and fiber parts, brake and steering systems and glass and upholstery to ensure consistent production quality. Minimizing transportation costs by selecting nearby suppliers is essential. Sustainability and supply chain risks must be assessed, and long-term contracts should be negotiated to stabilize pricing and ensure a steady supply.
• Safety and Environmental Compliance: Safety protocols must be implemented to address the reactive nature of e-rickshaw. Advanced monitoring systems should be installed to detect leaks or deviations in the process. Effluent treatment systems are necessary to minimize environmental impact and ensure compliance with emission standards.​
• Quality Assurance Systems: A comprehensive quality control system should be established throughout production. Analytical instruments must be used to monitor product concentration, purity, and stability. Documentation for traceability and regulatory compliance must be maintained.

Project Economics:

​Establishing and operating an e-rickshaw manufacturing plant involves various cost components, including:​

• Capital Investment: The total capital investment depends on plant capacity, technology, and location. This investment covers land acquisition, site preparation, and necessary infrastructure.
• Equipment Costs: Equipment costs, such as those for metal fabrication equipment, painting and coating machines, electrical assembly tools, plastic injection molding machines, vehicle assembly lines, testing equipment and miscellaneous tools, represent a significant portion of capital expenditure. The scale of production and automation level will determine the total cost of machinery.​
• Raw Material Expenses: Raw materials, including metal body structure, battery, electric motor, axles and suspension, tyres, plastic and fiber parts, brake and steering systems and glass and uphosltery, are a major part of operating costs. Long-term contracts with reliable suppliers will help mitigate price volatility and ensure a consistent supply of materials.​
• Infrastructure and Utilities: Costs associated with land acquisition, construction, and utilities (electricity, water, steam) must be considered in the financial plan.
• Operational Costs: Ongoing expenses for labor, maintenance, quality control, and environmental compliance must be accounted for. Optimizing processes and providing staff training can help control these operational costs.​
• Financial Planning: A detailed financial analysis, including income projections, expenditures, and break-even points, must be conducted. This analysis aids in securing funding and formulating a clear financial strategy. 

Capital Expenditure (CapEx) and Operational Expenditure (OpEx) Analysis:

Capital Investment (CapEx): Machinery costs account for the largest portion of the total capital expenditure. The cost of land and site development, including charges for land registration, boundary development, and other related expenses, forms a substantial part of the overall investment. This allocation ensures a solid foundation for safe and efficient plant operations.

Operating Expenditure (OpEx): In the first year of operations, the operating cost for the E-Rickshaw manufacturing plant is projected to be significant, covering raw materials, utilities, depreciation, taxes, packing, transportation, and repairs and maintenance. By the fifth year, the total operational cost is expected to increase substantially due to factors such as inflation, market fluctuations, and potential rises in the cost of key materials. Additional factors, including supply chain disruptions, rising consumer demand, and shifts in the global economy, are expected to contribute to this increase.

Capital Expenditure Breakdown:

Operational Expenditure Breakdown:

Profitability Analysis:

Report Coverage:

Report Customization

While we have aimed to create an all-encompassing e-rickshaw plant project report, we acknowledge that individual stakeholders may have unique demands. Thus, we offer customized report options that cater to your specific requirements. Our consultants are available to discuss your business requirements, and we can tailor the report's scope accordingly. Some of the common customizations that we are frequently requested to make by our clients include:

• The report can be customized based on the location (country/region) of your plant.
• The plant’s capacity can be customized based on your requirements.
• Plant machinery and costs can be customized based on your requirements.
• Any additions to the current scope can also be provided based on your requirements.

Why Buy IMARC Reports?

• The insights provided in our reports enable stakeholders to make informed business decisions by assessing the feasibility of a business venture.
• Our extensive network of consultants, raw material suppliers, machinery suppliers and subject matter experts spans over 100+ countries across North America, Europe, Asia Pacific, South America, Africa, and the Middle East.
• Our cost modeling team can assist you in understanding the most complex materials. With domain experts across numerous categories, we can assist you in determining how sensitive each component of the cost model is and how it can affect the final cost and prices.
• We keep a constant track of land costs, construction costs, utility costs, and labor costs across 100+ countries and update them regularly.
• Our client base consists of over 3000 organizations, including prominent corporations, governments, and institutions, who rely on us as their trusted business partners. Our clientele varies from small and start-up businesses to Fortune 500 companies.
• Our strong in-house team of engineers, statisticians, modeling experts, chartered accountants, architects, etc. has played a crucial role in constructing, expanding, and optimizing sustainable manufacturing plants worldwide.