Indian manufacturer investing ₹300 crore in composite materials facility to achieve ECE 22.06 certification and ₹1,300 crore turnover.
Helmet Maker Targets 60,000 Units/Day Capacity in ₹1,300 Crore Expansion Push
New Delhi— Indian helmet manufacturer Steelbird has unveiled ambitious plans to build the country’s first fully integrated carbon fiber helmet production facility, marking a significant leap in domestic personal protective equipment manufacturing. The expansion aims to boost daily production capacity to 60,000 helmets while achieving ₹1,300 crore annual turnover.
Key Expansion Highlights
🛡️ New Carbon Fiber Plant: First in-house weaving facility for composite materials
🏭 Existing Infrastructure: 1M+ sq ft across 9 plants in Baddi & Noida
💰 Recent Investments: ₹40 crore in EPS/EPP/decals infrastructure
🌍 Global Ambitions: Targeting ECE 22.06 certification for European exports
Manufacturing Breakthroughs
1. Vertical Integration Strategy
| Component | Production Capability | Innovation Focus |
|---|---|---|
| Carbon Fiber Shells | New weaving facility | Hybrid material R&D |
| EPS Liners | 45,000 units/day | Multi-density impact zones |
| Visors | Anti-fog, anti-scratch coatings | Photochromic tech |
| Hardware | Buckles, rivets, straps | Quick-release systems |
2. Carbon Fiber Technology Roadmap
✔ Material Control: End-to-end production from raw fiber to finished shell
✔ Performance Targets:
- 30% weight reduction vs conventional helmets
- 15% better impact absorption
✔ Certification Path: From current DOT to ECE 22.06 and FIM racing standards
Market Expansion Plans
Production Scale-Up
📈 Current Output:
- 45,000 EPS helmets/day
- 5,000 premium composite helmets
🚀 2026 Targets:
- 60,000 total units/day
- 20% production for export markets
Product Development
🆕 New Models: 5-7 carbon fiber designs in pipeline
⏱️ Development Cycle: 2-3 years per model
💡 R&D Investment: ₹1.5-10 crore per helmet design
Leadership Vision
Rajeev Kapur, Managing Director:
“Our carbon fiber facility will revolutionize helmet safety in India. By controlling every thread of raw material, we can engineer solutions that outperform global benchmarks while maintaining affordability.”
Industry Context: India’s Helmet Market
🛵 Market Size: ₹3,800 crore (20% CAGR)
🛡️ Safety Gap: 65% of helmets sold fail ISI standards
🌐 Export Potential: $200M ASEAN/Africa opportunity
Competitive Edge
- vs Imported Brands: 40% cost advantage
- vs Local Makers: Only fully integrated manufacturer
- Tech Differentiator: In-house material science expertise
Facility Specifications
Baddi Manufacturing Hub
🏗️ Area: 600,000 sq ft
🤖 Automation: Robotic molding for consistency
♻ Sustainability: Closed-loop resin recycling
Upcoming Carbon Fiber Plant
🔬 Clean Rooms: ISO Class 8 standard
🧵 Weaving Tech: 3D interlacing capability
🧪 Testing Labs: CT scanning for defect detection
Financial & Employment Impact
💰 CAPEX Plan: ₹300 crore phased investment
👷 Job Creation: 1,500+ skilled positions
📦 Value Chain: 200+ MSME vendors to be onboarded
