Brushless fans, integrated diagnostics, and intelligent thermal management engineered into products ensure optimal battery efficiency, power electronics protection, and cabin comfort for next-generation vehicles, writes Upendra Kasbekar.

In  Electric Vehicles (EVs), thermal management is a derivative of battery efficiency, power electronics protection, cabin comfort, and intelligent energy management. Italian thermal solutions specialist SPAL Automotive, through its Indian arm SPAL India Pvt. Ltd., is making bold strides to meet these emerging demands. At the Auto Components Show 2025, SPAL India made a notable presence by showcasing its advanced range of electric fans and blowers. Ninan Philip, Director (Sales & Marketing), SPAL Automotive, has given deeper insights into the company’s roadmap and how it plans to shape India’s EV and mobility landscape.

EVs Bring A New Cooling Equation

Electric vehicles, as Mr. Philip pointed out, have changed the dynamics of thermal management. “Earlier, thermal management was largely restricted to engine cooling and HVAC. Now, it’s an ecosystem approach. Batteries, inverters, converters, on-board chargers, everything requires precise thermal control,” he explained. SPAL’s product portfolio for the Indian market includes high-performance brushless fans and blowers that are specifically designed to meet these modern requirements. The BLDC motor-driven fans are not only compact and efficient but also operate with low noise and high reliability an essential feature for EV applications, Philip explained.“Our R&D is focused on helping OEMs achieve greater thermal stability with less energy consumption. We’re not just building fans; we’re building smart thermal modules that talk to the vehicle’s brain,” he claimed.

The Growing Need

With EV penetration increasing, the need for advanced thermal management solutions is a given. Overheating is a known menace and is linked to reduced range, faster charge degradation, and, in extreme cases, thermal runaway leading to catastrophic incidents including loss of life. These cooling systems help mitigate temperature fluctuations and prevent the battery from reaching unsafe levels, ensuring reliable performance throughout the vehicle’s lifespan.

Power electronics become more compact, requiring precise thermal control to avoid overheating. Inverters, converters, and onboard chargers, essential components in EVs, all rely on efficient cooling systems to operate optimally. The failure to manage the heat generated by these components can lead to inefficiencies, system failure, or even safety hazards. Beyond electric vehicles, the rise of alternative fuel vehicles, hydrogen-powered buses, and autonomous vehicles further expands the scope for advanced thermal management. The evolving mobility ecosystem demands a shift towards integrated cooling systems that can cater to diverse thermal needs across various vehicle types. As such, thermal solutions are moving beyond traditional cooling, evolving into smart systems that can adapt to dynamic thermal loads and provide real-time diagnostics.

The Indian Market Mandate

As India ramps up its EV mission both in passenger and commercial vehicle segments, SPAL is keen on localisation and customization. Unlike Western markets, Indian road conditions, climatic variations, and duty cycles demand a different engineering lens. “One-size-fits-all doesn’t work here. That’s why we’re heavily investing in application engineering and simulation capabilities in India,” said Philip. He informed that SPAL is working closely with OEMs to tailor cooling solutions specific to battery packs, motor controllers, and cabin systems used in Indian-made EVs. SPAL’s range of brushless axial fans in the 200–500 mm range, radial blowers, and integrated control units are all designed to support Battery Thermal Management Systems (BTMS), power electronics, and cabin HVACs. Most of these products comply with IP68 and IP6K9K ratings for dust and water resistance, making them ideal for rugged Indian use.

Tapping Future Mobility

While EVs are a key focus area, SPAL is also eyeing future mobility in a broader sense. It is looking at opportunities within hydrogen fuel cells, autonomous vehicles, and even next-gen IC engine platforms that require smart cooling modules. The company’s brushless motors come with LIN and PWM control options will aid seamless communication with vehicle ECUs and respond dynamically to thermal loads in a unique manner. “Future mobility isn’t a single lane. It’s a highway with EVs, hybrids, fuel cell vehicles, and even intelligent logistics platforms all requiring unique cooling strategies. Our strength lies in anticipating these changes,” he reiterated.

SPAL’s collaboration with global automotive players allows it to transfer learnings from Europe, the US, and Japan to the Indian context. But India is not just a recipient, it’s becoming a design and development hub.“We are working on projects where the thermal system design is being led from India,” said Philip. “That’s a big leap for our local engineering team and an indication of how seriously we take India’s role in our global strategy,” he concluded.