Exhaust System Market

[339 Pages Report] The global exhaust system market size was valued at USD 32.9 billion in 2024 and is expected to reach USD 40.6 billion by 2030, growing at a CAGR of 3.6% during the forecast period. Exhaust gases released from engine cylinders are collected and cooled by the exhaust manifold before being directed to the catalytic converter via the downpipe. The catalytic converter and other after-treatment devices purify these gases by removing harmful pollutants. The gases then pass through the muffler, which reduces noise levels and finally emitted as cleansed exhaust through the tailpipe. The exhaust system comprises an exhaust manifold, downpipe, catalytic converter, various sensors (oxygen, temperature, etc.), mufflers, resonators, clamps, and tailpipes. Additionally, the exhaust system includes various after-treatment devices, alongside the catalytic converter, to eliminate harmful components such as carbon monoxide (CO), carbon dioxide (CO2), nitrogen oxides (NOX), and particulate matter (PM) from the exhaust gas. After-treatment devices installed in diesel engines include diesel particulate filters (DPF), diesel oxidation catalysts (DOC), lean NOX traps (LNT), and selective catalytic converters (SCR), while gasoline engines utilize gasoline particulate filters (GPF).

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Market Dynamics

DRIVER: Increasing use of after-treatment device combination.

Reducing pollutants from diesel engines in the vehicle sector remains a significant scientific and technological challenge, especially with increasingly stringent regulations. Meeting strict limits on NOx and soot emissions requires complex catalytic systems that lead to the fitment of larger units, which consume more fuel. The combination of after-treatment devices enables automotive OEMs and exhaust system manufacturers to limit vehicle emissions within required regulatory restrictions. Therefore, effective after-treatment devices for diesel vehicles necessitate integrated catalyst technologies to reduce exhaust gas emissions individually. Selective catalytic reduction (SCR) and lean NOx trap (LNT) are key technologies for reducing NOx under lean-burn operation conditions, while soot removal primarily relies on filters (DPFs). These devices are typically used sequentially or in combinations to address the limitations of individual devices. One of the most commonly employed combinations of after-treatment devices consists of SCR and DPF. This pairing effectively eliminates over 70% of gaseous pollutants and particulate matter. In this system, SCR converts NOX into nitrogen and water using a reductant, while DPF filters out particulate matter.

In diesel vehicles, the focus is primarily on reducing PM and NOx emissions, typically addressed through a combination of DPFs and SCR systems. For example, BASF’s Catalysts division offers the combination of a Diesel Oxidation Catalyst (DOC) and a Lean NOx Trap (LNT). This DOC and LNT combination offers high HC and CO removal efficiency of a fully formulated DOC, with the ability of an LNT to trap and reduce NOx. Other possible combinations are SCR-on-Filter (SCRoF), series configurations like LNT/DPF and SCR/DPF, and hybrid systems like LNT/DPF and SCR/DPF. These combinations allow exhaust systems to control the emissions efficiently, which are set in Euro 6 standards for diesel engines. Further, in gasoline vehicles, the emphasis is often on reducing CO, HC, and NOx emissions; hence, catalytic converters are paired with advanced catalyst formulations. By integrating these technologies, automotive exhaust systems can achieve comprehensive emission control across different pollutants, resulting in cleaner exhaust emissions and improved air quality. Such combinations are expected to continue dominating in the coming years, leading to a high demand for after-treatment devices and subsequent growth of the exhaust system market.

RESTRAINT: Increasing Sales of Cleaner Vehicles

Emission norms worldwide are becoming more stringent each year. Consequently, there is an increasing demand to reduce exhaust gas emissions. CNG and LPG-powered vehicles use simpler versions of exhaust systems without any after-treatment devices like DPF, DOC, SCR, LNT, or GPF. This decreases the revenue generation of the exhaust system industry compared to ICE-powered vehicles.

Unlike IC engines, which leverage automotive exhaust and after-treatment devices to reduce emissions and improve fuel efficiency, EVs draw power directly from batteries without requiring any form of forced induction. As consumers increasingly opt for EVs, there is a foreseeable decline in the demand for automotive exhaust systems. This trend is evident in the automotive industry, where leading manufacturers such as BMW, Volkswagen, GM, Stellantis, and Toyota are shifting focus toward EV development in response to stringent EU emission standards. BMW aims to achieve significant EV sales by 2030, with Volkswagen targeting a substantial portion of its European sales to be EVs by the same year. GM has committed to discontinuing polluting vehicle production by 2035, while Stellantis plans to pivot toward electric and hybrid vehicles, aiming for a majority of sales in that segment by 2030. Similarly, Toyota prioritizes hybrid sales and reduces reliance on traditional internal combustion engines, aiming for a substantial share of hybrid sales by 2025.

EVs emit fewer greenhouse gases than traditional internal combustion engines like gasoline and diesel cars. As the electric grid transitions to zero-carbon power sources, emissions from EVs are expected to decrease even further. The increase in sales is also due to lucrative subsidies and incentives provided by governments. As more consumers switch to EVs and governments implement stricter emissions regulations, the demand for automotive exhaust systems is likely to decline during the forecast period.

OPPORTUNITY:Increasing demand for lightweight and efficient exhaust systems to reduce vehicle weight

The demand for vehicle weight reduction is continuously growing to comply with stringent emission and fuel economy regulations and avoid heavy penalties imposed by government agencies. Reducing vehicle weight significantly lowers fuel consumption and CO2 emissions, as lighter cars require less fuel to overcome inertia, thus reducing the power needed to propel the vehicle. As per industry experts, reducing vehicle weight by 10% can boost its mileage by almost 6% to 8% and increase fuel economy.

Automotive OEMs are working on several aspects, like new and lightweight materials, aerodynamic design, and drive train (engine/transmission) efficiency, to reduce the overall vehicle weight. Conventional exhaust systems use materials like cast iron, stainless steel, mild steel/carbon steel, and others. However, several automotive OEMs and manufacturers focus on reducing the weight of exhaust systems and their components. One key material that has gained prominence is stainless steel, specifically high-grade stainless steel alloys such as 304 and 316. These alloys offer exceptional corrosion resistance, durability, and thermal stability, making them ideal for exhaust components exposed to high temperatures and harsh environments. Stainless steel also provides a balance between strength and weight, allowing for the creation of exhaust systems that are both robust and lightweight, thereby improving fuel efficiency and reducing emissions.

Exhaust system manufacturers worldwide are working toward lowering the weight of exhaust systems and increasing vehicle fuel economy. Hence, exhaust systems with lightweight materials would be a cost-effective choice in the coming years, as electric and hydrogen vehicles will take time to replace ICE vehicles.

CHALLENGE: Lack of uniformity in emission regulations across different regions

Automotive manufacturers operate in a global market but must adhere to varying emission standards set by different countries and regions. This lack of uniformity not only complicates the design and manufacturing process for exhaust systems but also increases costs associated with compliance. Engineers and designers must develop exhaust systems that meet the most stringent regulations worldwide, resulting in complex and often region-specific designs to ensure compliance. Moreover, the absence of standardized regulations makes it difficult for manufacturers to achieve economies of scale in production, as they may need to tailor exhaust systems for different markets, further driving up costs and complicating supply chains.

Furthermore, the lack of standardization in emission regulations hampers innovation and technological advancements in automotive exhaust systems. Manufacturers need help investing in R&D activities for new exhaust system technologies when regulatory requirements vary significantly between regions. This fragmentation in regulations restricts innovation as manufacturers focus on meeting existing standards rather than developing groundbreaking solutions for emissions reduction. Ultimately, achieving global standardization in emission regulations would streamline the design and manufacturing process for automotive exhaust systems, encourage innovation, and drive down costs, benefiting both manufacturers and consumers alike. However, once such standardization is realized, the automotive industry will continue to struggle with the challenges posed by disparate emission regulations across different regions.

Exhaust System Market Ecosystem.

The major manufacturers in the exhaust system market have the latest technologies, diversified portfolios, and strong global distribution networks. The major players in the market are Tenneco Inc., , FORVIA Faurecia, Continental AG, Eberspacher, and Futaba Industrial Co., Ltd. The ecosystem analysis highlights various players in the market ecosystem, which component providers, exhaust system manufacturers, and automotive OEMs primarily represent.

The sensors segment holds the largest market share by component segment in the exhaust system market.

PM sensors are installed exclusively in diesel vehicles equipped with a DPF. Temperature, NOX, and oxygen sensors are used in both gasoline and diesel engines. In an exhaust system, one temperature sensor is used in gasoline engines, while diesel engines use two. Additionally, two oxygen sensors are employed for each catalytic converter in all vehicle types studied. Global emission reduction targets are anticipated to boost the use of exhaust sensors in vehicle exhaust systems to capture, monitor, and analyze emission gases and their quantities, thereby driving the demand for sensors during the forecast period.

The Asia Pacific region's large vehicle production, combined with recent emission norms such as BS 6 (India) and China 6 (China), is expected to drive the sensors (OE) market during the forecast period. Governments around the world are imposing more emission standards to reduce air pollution. This has compelled industries, especially the automotive sector, to implement advanced technologies for emissions control, resulting in a higher demand for NOx sensors. The advancement of high-performance exhaust technologies, such as gasoline particulate filters (GPF) and advanced exhaust heat recovery systems, is expected to drive market growth and demand additional sensors for optimization.

The GPF is estimated to be the fastest-growing after-treatment device segment during the forecast period.

The GPF segment is projected to grow at the highest CAGR during the forecast period. The adoption rates of different after-treatment technologies vary across different fuel types. The market for after-treatment devices such as DOC, DPF, LNT, and SCR for diesel vehicles is reaching maturity. This is happening alongside a decreasing acceptance of diesel fuel due to strict laws and higher associated taxes, especially in developed regions like Europe and North America. Alternatively, the GDI engines have experienced rapid adoption in recent years across Europe, the US, and key Asia Pacific markets such as China and India. GDI engines offer key advantages such as improved fuel efficiency, higher power output, and reduced emissions compared to traditional port fuel injection systems. It is also cost-effective for OEMs in production, and consumer preferences are shifting towards more environmentally friendly and technologically advanced vehicles. However, the combustion characteristics of GDI engines also lead to increased production of particulate matter, compelling the fitment of Gasoline Particulate Filters (GPF) as after-treatment devices to mitigate harmful emissions effectively. The current adoption of GDI engines in Asia is significant, with a projected upward trend in the future as emission standards become stricter, and OEMs are compelled to integrate GDI engines into their vehicle line-ups to remain competitive in the market. As consumer demand for fuel-efficient vehicles grows, GDI engines and GPF technologies will notice an increased adoption in the coming years.

Asia Pacific holds the largest market for exhaust system in 2024.

Asia Pacific is expected to dominate the global exhaust market during the forecast period. This market dominance can be attributed to the growing production of vehicles. The increasing production volume of automobiles in recent years, combined with current emission regulations in countries like China (China VI) and India (BS-VI) and upcoming regulations like China VII and BS VII, is expected to fuel the growth of the exhaust system market in the Asia Pacific during the forecast period.

In the Asia-Pacific region, China holds the largest market for exhaust systems due to its increased vehicle production. Since 2019, implementing China V emission norms has led to a 100% adoption rate of DOC and DPF across all vehicle types, although the adoption rate of SCR remains lower compared to European countries. The forthcoming China VI emission norms drive the anticipated growth in various after-treatment devices. Japan ranks as the second-largest exhaust system market in the Asia-Pacific, adhering to its own stricter emission standards. Since 2018, Japan has achieved a 100% adoption rate of DOCs and DPFs for all vehicle types. It is projected that by 2025, the adoption rate of SCR will reach 100% for passenger cars and LCVs and by 2021 for buses and trucks. India is expected to be one of the fastest-growing markets in the Asia-Pacific. As of 2020, India's adoption rate for all after-treatment devices, such as SCR, LNT, and GPF, is lower than other countries in the region. However, the adoption rate for DPF and DOC increased to 100% across all vehicle types with the implementation of BS VI emission norms in 2020. The adoption rate for various after-treatment devices is anticipated to rise further in the coming years, driven by the introduction of more stringent emission regulations.

Major players in this market include Futaba Industrial Co., Ltd. (Japan), Sango Co. Ltd. (Japan), Yutaka Giken Company Limited (Japan), Sejong Industrial Co., Ltd. (South Korea), Hirotec Corporation (Japan), Sharada Motor Industries Limited (India), and Marelli Holdings Co. Ltd. (Japan).

Key Market Players

The key companies operating in the exhaust system market are Tenneco Inc.(US), Faurecia (France), Eberspächer  (Germany), Friedrich Boysen GMBH & CO. KG (Germany), and BENTELER International (Austria).

These companies adopted new product launches, expansion, partnerships, and joint ventures to gain traction in the exhaust system market.

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Scope of the Report

Along with the given market data, MarketsandMarkets offers customizations in accordance with the company’s specific needs.

The study segments the exhaust system market:

OE Market, by after-treatment device

• DOC
• DPF
• SCR
• LNT
• GPF

OE Market, by component

• Manifolds
• Downpipes
• Catalytic Converter
• Mufflers
• Tailpipes
• Sensors
• Hangers

OE Market, By Vehicle type

• Passenger Cars
• LCVs
• Buses
• Trucks

By Fuel type

• Diesel
• Gasoline

By Sales Channel

• OEM
• Aftermarket

Aftermarket, by after-treatment device

• DOC
• DPF
• GPF
• SCR

Off-Highway (OE) market, by Equipment Type

• Agricultural tractor
• Construction Equipment
• Mining Equipment

Off-highway (OE) market, by after-treatment device

• DPF
• DOC
• SCR

By Region

• Asia Pacific
• North America
• Europe
• Rest of the World [RoW]

Recent Developments

• In January 2024, Continental AG revealed plans for a new hydraulic hose production plant in Mexico. The proposed investment is approximately USD 90 million, marking one of the company’s significant investments in 2024. This upcoming facility will serve industrial purposes and is poised to enhance Continental’s regional manufacturing capabilities. The plant is expected to create over 200 employment opportunities in its initial phase.
• In November 2023, Eberspächer’s facility, spanning over 7,000 square meters, will manufacture exhaust gas after-treatment systems for passenger cars and commercial vehicles intended for Chinese automotive brands. This encompasses hot-end systems comprising catalytic converters, particulate filters, and cold-end components such as mufflers and pipes.
• In October 2023, Purem AAPICO, a joint venture between Eberspaecher and AAPICO Hitech, inaugurated its new facility in Rayong, Thailand. Situated 100 km southeast of Bangkok, the production site will manufacture exhaust systems for a pickup truck model of a prominent US automotive company.
• In October 2023, Tenneco Inc.’s pioneering Cold Start Thermal Unit (CSTU) represents a groundbreaking heat source for after-treatment systems in passenger cars, light-duty vehicles, and commercial vehicles. This innovative technology empowers OEMs to adhere to ever-stringent emissions regulations effectively. Catering to gasoline and diesel applications, CSTU technology is tailored to meet upcoming Euro 7 standards by delivering thermal energy directly and efficiently. It ensures consistent catalyst performance throughout the engine’s operational spectrum, focusing on crucial phases like initial start-up and prolonged idling, which are significant sources of regulated emissions.
• In May 2023, FORVIA Faurecia (FORVIA) signed an agreement with Cummins to transfer two Faurecia manufacturing plants located in Roermond, the Netherlands, and Columbus, Indiana, the US, and their associated activities to Cummins. The agreement integrated these plants and their employees into Cummins’ worldwide operations, ensuring long-term viability.
• In November 2022, Continental AG inaugurated its Technical Center India campus in Bengaluru with an investment of Rs 1,000 Crore (approximately USD 128.1 million). This new campus has the capacity to accommodate over 6,500 employees. It will be a hub for consolidating India's growing engineering capabilities and teams, focusing on local and global markets' Automotive Research and Development (R&D) needs.
• In April 2022, Continental AG broadened its product portfolio to incorporate exhaust gas temperature sensors (EGT sensors) for Volkswagen Group’s VW, Audi, Skoda, and Seat brands.

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