Steelbird to Set Up Seventh Manufacturing Plant in Baddi, Targets 2.5 Crore Helmet Capacity by 2032

Steelbird Hi-Tech India Ltd. has announced plans to establish its seventh manufacturing facility in Baddi, Himachal Pradesh, as part of its long-term expansion strategy. The company said the new plant will increase its annual helmet production capacity to 2.5 crore units by 2032 from the current 1.5 crore units.

Spread across 22 acres, the integrated manufacturing campus will have nearly 15 lakh sq. ft. of built-up space upon completion. The facility is designed to produce up to 1 crore helmets annually and will form part of Steelbird's existing manufacturing network, which includes six plants in Baddi and three automated facilities in Noida.

The company said the new plant will also manufacture advanced energy management materials such as Expanded Polypropylene (EPP) and Expanded Thermoplastic Polyurethane (E-TPU), which are used in helmet construction to improve impact absorption while reducing weight.

Steelbird currently manufactures key helmet components in-house, including shells, EPS liners, visors, buckles, retention systems, interiors and packaging materials. According to the company, this integrated manufacturing approach is intended to maintain quality control and production consistency.

The company also outlined its product development plans, stating that it introduces more than 10 new helmet models each year. Development of each model takes between 18 and 24 months, with investments ranging from ₹1.5 crore to ₹5 crore depending on the complexity of the product. The development process covers design, engineering, tooling, prototyping, testing and homologation.

Steelbird said its five-year product roadmap includes premium helmets, Bluetooth-enabled smart helmets, helmets with integrated lighting systems, advanced composite helmets and products certified to multiple international safety standards.

"The seventh manufacturing plant represents our vision for the future, where innovation, technology and manufacturing come together to deliver safer, lighter and more advanced helmets. As demand for certified protective gear continues to grow, we are investing today to build the manufacturing capabilities of tomorrow," said Rajeev Kapur, Managing Director, Steelbird Hi-Tech India Ltd.