With years of engineering expertise, Surya Electric (Surya Mfr. Tube Mills) is contributing to India’s rapidly modernising tube and pipe machinery landscape. As the sector enters a decade defined by automation, digital intelligence, and sustainability, the company is helping drive the shift from traditional manufacturing to data-driven, high-precision production systems. In an exclusive interview with Tube & Pipe India, Mr. Suraj Bhan Sharma, CMD, Surya Electric (Surya Mfr. Tube Mills), talks about adopting disruptive technologies such as Direct Forming Technology (DFT), AI-enabled predictive maintenance, and digital twins. He also talks about adopting smart manufacturing technologies across operations.
Tube & Pipe India: If you had to define the current decade for the Indian tube and pipe industry in one phrase, what would it be, and why?
Suraj Bhan Sharma: This phrase reflects how the Indian tube and pipe industry is rapidly scaling its manufacturing capacity while embracing automation, digital controls, and sustainable practices. With growing demand from infrastructure, automotive, energy, and solar sectors, companies are not just expanding, they’re evolving with smarter, more efficient technologies to stay globally competitive.
TPI: Where do you see India’s manufacturing edge emerging: cost, quality, or innovation? How is your company positioning itself to lead on that front?
SS: India’s manufacturing edge is increasingly emerging at the intersection of cost efficiency and quality, with innovation becoming a strong upward trend. While competitive pricing remains a key strength, global buyers are now recognizing the consistent improvement in Indian-made quality and smart engineering solutions.
At Surya Electric (Surya Mfr. Tube Mills), we position ourselves by investing in advanced automation, precision machinery, and custom-engineered solutions ensuring we don’t just compete on cost, but lead with quality and reliability. Our in-house R&D and 30+ years of expertise allow us to deliver tailored, high-performance machinery that meets global standards, pushing Indian manufacturing ahead with confidence.
TPI: What is the single most disruptive technology or process upgrade you’ve implemented recently, and how has it changed your cost or performance curve?
SS: The most disruptive upgrade we’ve recently implemented is the integration of Direct Forming Technology (DFT) in our tube mill systems. Unlike conventional roll forming, DFT eliminates the need for multiple roll sets by allowing the production of various tube sizes on a single line without roll changeover.
This innovation has drastically reduced downtime, tooling costs, and setup times, while enhancing production flexibility and dimensional accuracy. The result is a significant shift in our performance curve: higher output, faster delivery, and greater cost efficiency making our offering far more competitive in both domestic and international markets.
TPI: Beyond automation, how are you leveraging data, AI, or digital twins to reimagine efficiency or product design in your plants?
SS: Beyond automation, we are actively leveraging real-time data analytics, AI-driven predictive maintenance, and digital twin technology to transform how we manage efficiency and design at Surya Electric – Surya Mfr. Tube Mills.
Digital twins of our tube mills and roll forming lines enable us to simulate performance, test design modifications virtually, and optimize machine parameters before physical deployment reducing trial-and-error time. AI algorithms monitor machine health, predict failures, and recommend maintenance schedules, significantly minimizing downtime and unplanned halts.
This integration of smart tech has allowed us to move from reactive to proactive operations, leading to higher output consistency, better energy efficiency, and faster product development cycles strengthening our position as a future-ready manufacturer.
“While competitive pricing remains a key strength, global buyers are now recognizing the consistent improvement in Indian-made quality and smart engineering solutions.”
TPI: Sustainability is now a boardroom conversation. How are you balancing decarbonisation targets with profitability and competitiveness?
SS: At Surya Electric (Surya Mfr. Tube Mills), sustainability is not just a conversation it’s part of our long-term strategy. We are actively balancing decarbonisation with profitability by integrating energy efficient technologies, optimizing material usage, and adopting low-waste production practices.
Our HF welders, automated roll forming lines, and smart drives are designed to reduce energy consumption per ton of output. We also use digital monitoring to track energy, emissions, and resource usage in real time helping us make informed decisions that cut costs while supporting our environmental goals.
By aligning sustainability with process efficiency, we stay competitive globally while responsibly contributing to India’s green manufacturing shift.
TPI: In the metals and manufacturing sectors, recycling and material efficiency are game changers. What steps has your organisation taken to close the loop?
SS: At Surya Electric (Surya Mfr. Tube Mills), we recognize that material efficiency and recycling are crucial for long-term competitiveness and environmental responsibility. To close the loop, we’ve implemented scrap management systems that capture, segregate, and recycle metal waste generated during production minimizing raw material loss and reducing overall costs.
We’ve also optimized our coil slitting and cut-to-length lines to maximize yield from every coil and minimize edge scrap. Our design philosophy emphasizes precision tooling and automation to reduce defects and rework.
By collaborating with trusted recyclers and reintroducing usable scrap into non-critical production cycles, we’re moving steadily toward a circular manufacturing model, reinforcing both sustainability and operational efficiency.
TPI: Among technology partnerships, joint R&D, and co-branding with downstream users, which form of collaboration do you find most valuable, and why?
SS: Among the various forms of collaboration, joint R&D stands out as the most valuable for us at Surya Electric – Surya Mfr. Tube Mills. It enables deep, technical synergy where both partners bring their expertise to co-develop next-generation solutions tailored to evolving industry needs.
Through joint R&D, we can innovate faster, customize machinery for specific applications (like solar torque tube, auto components, or crash barriers), and stay ahead of global quality and performance benchmarks. This collaborative innovation not only strengthens product value but also builds long-term relationships based on shared success.
While technology partnerships and co-branding have their place, it’s co-creation through R&D that truly drives differentiation and future-readiness.
“Our HF welders, automated roll forming lines, and smart drives are designed to reduce energy consumption per ton of output.”
TPI: Government schemes like PLI and Gati Shakti are shaping supply chains. What tangible impact are you witnessing on ground, i.e., in demand, policy clarity, or infrastructure?
SS: Government initiatives like PLI (Production Linked Incentive) and Gati Shakti are creating visible momentum in India’s industrial ecosystem. On the ground, we’re seeing increased demand from sectors like infrastructure, automotive, and renewable energy, as these schemes stimulate large-scale investments and capacity expansion.
PLI is driving localization, encouraging OEMs and component manufacturers to set up facilities domestically, which in turn boosts demand for our advanced tube mills, slitting lines, and roll forming machines. At the same time, Gati Shakti is enhancing logistics and connectivity, reducing transit time for raw materials and finished goods critical for cost effective operations.
Most importantly, there’s greater policy clarity and ease of doing business, especially in approvals and infrastructure planning. These reforms are not just macro enablers; they’re tangibly shifting the manufacturing narrative on the shop floor and across the supply chain.
Also Read: MKK Metal Sections: Powering the Infrastructure Surge with Intelligence and Innovation
TPI: If we were to revisit this conversation at the next edition of TPF, what milestone or transformation would you want to showcase?
SS: By the next edition of Tube & Pipe Fair, we aim to showcase a major milestone: our successful integration of smart manufacturing technologies across all Surya Electric (Surya Mfr. Tube Mills) operations including IoT-enabled tube mills, predictive maintenance systems, and real-time production analytics.
We also envision presenting our first fully digital production line, powered by AI for quality control, energy optimization, and zero-defect output. Additionally, we plan to highlight our growing global footprint, with exports to new strategic markets and expanded technical collaborations.
Ultimately, the transformation we want to showcase is Surya’s evolution from a trusted machine builder to a next-generation manufacturing intelligence partner helping customers move faster, cleaner, and smarter into the future.
TPI: Finally, what’s the one belief or leadership principle guiding you through this phase of rapid industrial evolution?
SS: The one core belief guiding us through this rapid industrial evolution is: “Adapt with purpose, lead with vision.”
At Surya Electric (Surya Mfr. Tube Mills), we believe that true leadership in a changing landscape comes not just from adopting new technologies, but from aligning every innovation with customer value, sustainability, and long-term impact. We stay rooted in integrity and agility embracing change while ensuring every step forward empowers our people, strengthens our partnerships, and contributes meaningfully to the future of manufacturing.
“Among the various forms of collaboration, joint R&D stands out as the most valuable for us at Surya Electric – Surya Mfr. Tube Mills. It enables deep, technical synergy where both partners bring their expertise to co-develop next-generation solutions tailored to evolving industry needs.”
