Martin Hanstein is Head of "Vehicle Technology, Performance Measurements, Tyres at the DLG Test Center in Gross-Umstadt, Germany. The test center offers independent testing and certification services for tractors, agricultural machinery, vehicle components, cabins, electronics, and farm inputs. Among its most prominent tests are the DLG PowerMix efficiency test and the OECD tractor codes. In addition, the DLG provides its own test frameworks and quality seals, which are widely recognized and trusted by the agricultural machinery industry as a mark of reliability and performance.
What are the biggest engineering challenges currently facing agricultural vehicle developers?
Agricultural vehicle developers face the unique challenge of building machines that must operate with absolute reliability under extreme real‑world conditions – dust, heat, vibration, and constant load – while system complexity continues to grow. Tractors and implements must communicate seamlessly, and increasingly large data streams have to be processed in real time. At the same time, productivity must rise, emissions must fall, and developers must tackle the electrification of high‑power machines, integrate alternative fuels, and manage rapidly expanding software and automation demands. Yet the vehicles must remain robust, cost‑effective, and serviceable for farmers. Compounding these challenges is the fact that production volumes in agriculture are far lower than in the automotive sector, meaning the engineering effort per unit is significantly higher. Balancing energy efficiency, digital technology, safety, durability, and real‑world operating constraints has become the central engineering task facing the industry – something we see every day at the DLG Test Center.
How long does a typical development program last?
Developing modern agricultural machinery, such as a tractor, is a complex and multi‑stage process that typically spans several years. Due to the comparatively low production volumes in agricultural machinery, development cycles tend to be longer than in the automotive sector, as engineering effort and validation intensity must be distributed across far fewer units. As a test center, we are directly involved in product development, giving us some insights into the engineering process. Our particular focus at the DLG Test Center lies on fuel‑consumption and performance testing for tractors, as well as homologation and certification services for all types of agricultural machinery and components, including—for example—cabs and protective structures.
How do regulations shape testing requirements? Are there any upcoming regulations affecting this sector?
Regulations are a key driver of our testing protocols. Looking ahead, the new EU Machinery Regulation, which takes effect in 2027, will introduce stricter rules for digital safety, cybersecurity, and autonomous functions. We are already preparing our test methods to cover these areas, so manufacturers can validate their machines efficiently and stay ahead of regulatory changes. To support the industry even more effectively, we have established a dedicated regulatory services division that assists manufacturers in understanding and implementing all relevant requirements — from documentation and conformity assessment to practical testing. In addition, we are designated by the KBA as a Technical Service, enabling us to perform the corresponding approval tests officially and provide manufacturers with a complete compliance and certification pathway from a single source.
What performance expectations from farmers drive new test programs?
DLG is in close contact with farmers. We work with around 40 working groups led by farmers and supported by academics, organizations and manufacturers, where we address key topics in vehicle engineering and agricultural machinery technology. Farmers expect tractors and machines that are highly reliable in everyday use, equipment that starts reliably, performs consistently under varying field conditions and keeps downtime to a minimum.
In addition, “Total Cost of Ownership” is becoming more important. Farmers want machines that remain cost‑effective over their entire lifecycle in terms of fuel use, maintenance, durability and serviceability.
These expectations directly drive new test programs at DLG, including assessments of alternative fuels, fuel efficiency, ISOBUS connectivity and other performance‑relevant criteria, so that manufacturers can validate their innovations under real‑world conditions. Manufacturers rely on these insights and on our independent testing services to ensure their products meet practical demands in the field.
What are the main differences passenger vehicle and agri vehicle development?
Passenger cars are developed for predictable road conditions and mass production, with a focus on comfort, aerodynamics and standardized safety tests. Agricultural vehicles, by contrast, must deliver high torque, hydraulic power and long‑term durability in extreme and highly variable environments. A tractor alone can accomplish very little; its true functionality arises only through the implements it operates. This makes reliable communication between tractor and implement essential for safe, efficient and precise operation. Unlike cars, tractors also integrate precision farming technology and autonomous functions, making their development far more customized and application‑driven.
What are the main differences in the testing?
At the DLG Test Center, testing includes the DLG PowerMix for fuel efficiency and performance, dynamometer tests for engine, PTO, and hydraulic output, as well as OECD Code tests for power and noise. Additionally, machines are benchmarked and can earn DLG quality seals based on strict, transparent criteria. These procedures help manufacturers validate efficiency, reliability, and compliance with international standards.
How do you simulate real agricultural duty cycles (soil resistance, cycles of heavy load, PTO use)?
We have recorded extensive real‑world duty cycles in the field, covering typical field operations and transport work. Based on this data, we replicate the corresponding load profiles on our test benches. Depending on tractor size, the cycles are scaled and reproduced to simulate actual operating conditions as realistically as possible.
To achieve this, we use a roller dynamometer that can additionally load the PTO and the tractor’s hydraulic system, allowing every recorded cycle to be precisely replayed. We can perform these tests under both hot and cold environmental conditions to reflect seasonal operation. This enables us to evaluate machines under repeatable, practice‑oriented load conditions and reliably assess their performance.
What are the key tests both virtual and physical?
Simulation is becoming increasingly important, just as in the automotive industry. Physical testing is costly and time‑consuming, and certain scenarios can only be covered virtually. Simulation helps reduce test effort, analyze critical load cases more efficiently, and optimize test programs. However, real‑world and bench testing remain indispensable, because only physical tests can fully validate durability, safety, and overall machine performance.
What about data acquisition equipment? Is data acquisition, management and processing as much of a challenge in the agri sector as it is in the passenger car market?
Yes, data acquisition is a major challenge in the agricultural sector as well. The equipment must deliver reliable data under harsh and highly variable field conditions while handling large data volumes from long operating hours. This is especially true in development, where entire drivelines are instrumented to measure torque and power flow. Managing, synchronizing, and processing these complex data sets is therefore just as demanding as in the passenger car sector, even though the underlying reasons differ.
Can you give any recent examples of testing challenges you've had to overcome?
Alternative powertrains are becoming increasingly important in agriculture as well. Electrification, alternative liquid fuels such as HVO, and gaseous fuels are gaining relevance, especially within the manufacturers’ development departments.
For us at the DLG Test Center, this means continuously upgrading our test benches to reliably assess these new technologies. We are adapting our infrastructure to safely and reproducibly test electric and hybrid machines, and we are also preparing for future hydrogen‑powered drivetrains.
Have you had to devise any new tests or equipment of late? If so, please explain in detail.
Our roller test bench is a high‑capacity chassis dynamometer for agricultural and heavy vehicles. It simulates real field and transport duty cycles on steel rollers while measuring drivetrain performance, PTO and hydraulic output, and fuel or AdBlue consumption under controlled load conditions. Just last year, we upgraded the system to test our first hydrogen‑powered vehicle.
Today, the DLG test bench in Groß‑Umstadt is one of Europe’s most powerful all‑wheel roller dynamometers, capable of testing tractors up to around 1,000 PS and applying up to 60 tons of simulated test mass, including fully custom drive cycles.
What engineering trends will most influence next-generation agricultural vehicles and the testing of them?
Three major engineering trends will shape next‑generation agricultural vehicles and the way we test them. First, alternative powertrains and fuels: manufacturers are pushing beyond Stage V toward real CO₂ reduction with HVO, RME, hybrid systems, etc., which means testing focuses on performance, emissions, and durability across multiple energy carriers and operating strategies. Second, autonomy and AI: (semi‑)autonomous tractors, field robots, and smart implements require verification of perception, safety logic, functional behaviour, and mixed‑fleet compatibility under controlled yet realistic field conditions. Third, digital hydraulics and deep connectivity: ISOBUS integration, electronic load‑sensing, over‑the‑air updates, and software‑based precision control expand testing from mechanical and hydraulic systems to high‑voltage architectures and software‑centric functions. In short, agricultural vehicle testing is shifting from isolated mechanical checks toward holistic, multidisciplinary validation under realistic agricultural scenarios.
Interview: Dr. Malene Conlong / DLG-Newsroom