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A model-based approach for the design and development of electrically heated catalyst (EHC) systems is presented. Based on experimental analysis of the EHC heat-up and catalytic behaviour, a detailed physico-chemical EHC model is developed. Within a total system simulation environment, different heat-up measures are compared for SULEV30 compliance. The simultaneous reduction of HC, NOx and GHG is revealed to be challenging, HC being the limiting factor for engine based thermal management. Regarding total energy consumption, a combined EHC and late PoI approach is favoured to meet emission limits. The developed operation strategy is presented in detail and confirmed by experimental findings.