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0 New Delhi, August 19, 2025 – India embarked on its ethanol blending journey in petrol over two decades ago, marking a significant shift toward sustainable fuel alternatives. The initiative began in 2003 with a modest 5% ethanol blend (E5), aimed at reducing reliance on imported fossil fuels and curbing greenhouse gas emissions. Over the years, the government has steadily increased this target, achieving a 10% blend (E10) by 2022. The latest milestone came in July 2025, when India successfully implemented a 20% ethanol blend (E20) nationwide, five years ahead of its original 2030 schedule. While this move has been hailed as a green triumph, it has sparked debates about the safety of E20 fuel for older vehicles not designed to handle higher ethanol levels.
The Evolution of Ethanol Blending in India
India’s ethanol blending program was launched under the Ethanol Blended Petrol Programme (EBPP) to leverage the country’s abundant agricultural resources, such as sugarcane and surplus grains, to produce bioethanol. The initial E5 rollout in 2003 was limited to nine states and four Union Territories, but it laid the foundation for a broader policy. By 2018, the government set an ambitious target of 20% blending by 2030, later advancing it to 2025 due to rapid progress. The recent achievement of E20 across the country reflects a strategic push to enhance energy security, save foreign exchange (over ₹1.40 lakh crore since 2014-15), and support rural economies by channeling payments to farmers.
The Ministry of Petroleum and Natural Gas (MoPNG) has emphasized that E20 offers environmental benefits, including a 30% reduction in carbon emissions compared to E10, and technical advantages like a higher octane rating (108.5 versus petrol’s 84.4), which improves engine performance. However, the rapid rollout has raised concerns, particularly for vehicle owners with older models not compliant with the new fuel standard.
Is E20 Safe for Non-Compliant Older Vehicles?
The safety of E20 fuel for vehicles manufactured before April 2023—when automakers began producing E20-compatible models—has become a contentious issue. Most older vehicles, especially those built before 2012, were designed for E10 or lower blends. The higher ethanol content in E20 introduces challenges due to ethanol’s corrosive nature and lower energy density.
Government officials and the Automotive Research Association of India (ARAI) assert that E20 is safe for all vehicles, backed by extensive testing over 100,000 km, which showed no significant engine damage or performance loss. The MoPNG claims that corrosion inhibitors in E20 fuel and adherence to Bureau of Indian Standards (BIS) specifications mitigate risks. For older vehicles, minor maintenance—such as replacing rubber gaskets or hoses after 20,000-30,000 km—is recommended as a routine measure, costing little during regular servicing.
However, automakers and vehicle owners paint a different picture. Companies like Toyota and Hero MotoCorp have cautioned that using E20 in non-compliant vehicles could void warranties and lead to long-term damage. Ethanol’s hygroscopic properties—its ability to absorb moisture—can corrode metal parts, degrade rubber components, and cause fuel system issues like leaks or clogged injectors. Reports from consumers, particularly on social media, highlight a 3-6% drop in mileage and instances of engine knocking or rough idling in older cars and two-wheelers.
A senior technical expert from a leading automaker, speaking anonymously, noted, “Older engines, especially those with basic metallurgy or pre-BS VI standards, weren’t engineered for E20’s chemical properties. Without upgrades like ethanol-resistant seals or ECU recalibration, damage could accumulate over time.” This view is echoed by car owners in coastal regions, where humidity exacerbates ethanol-related corrosion.
Mixed Reactions and Calls for Clarity
The government maintains that the mileage drop is marginal and can be managed with proper tuning, while dismissing claims of widespread damage as “unfounded” and lacking scientific backing. Union Minister Hardeep Singh Puri recently challenged critics to cite a single instance of E20-related vehicle failure, citing Brazil’s successful use of higher blends like E27.
Conversely, consumer groups and some manufacturers argue that the lack of choice at fuel pumps—where E10 is increasingly unavailable—leaves owners of older vehicles with no alternative. Punjab-based car critic Sunderdeep Singh suggested mandating clear labeling and offering multiple blends to protect non-compliant vehicles. Social media platforms are abuzz with complaints, with users reporting higher maintenance costs and questioning the government’s phased approach.
The Road Ahead
India’s transition to E20 is part of a broader roadmap that may include E27 by late 2025, as the Automotive Research Association of India works on engine compatibility studies. While the policy aligns with climate goals and economic benefits, the government faces pressure to address the needs of the country’s aging vehicle fleet, which includes millions of pre-2023 models.
For now, owners of older vehicles are advised to consult their manufacturer’s manual or service centers to assess compatibility. The Society of Indian Automobile Manufacturers (SIAM) is collaborating with the government to support vehicle owners, but experts call for a more transparent rollout, including public awareness campaigns and subsidies for retrofitting non-compliant vehicles.
As India races toward a greener future, the safety of E20 for older vehicles remains a critical issue, balancing innovation with the practical realities of its diverse automotive landscape.
Sources: Ministry of Petroleum and Natural Gas statements, industry expert insights, and consumer feedback.
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