Studds to Invest ₹150–160 Crore in Fifth Plant; Highest Automation Levels Planned

Helmet maker Studds Accessories Limited is investing around ₹150–160 crore in its upcoming fifth manufacturing facility, with the company indicating that the new plant will feature the highest levels of automation across its operations so far.

The facility, which is set to be commissioned in July 2026, is being developed in phases, with an initial investment of about ₹100 crore, followed by an additional ₹50–60 crore in the second phase.

Speaking to Autocar Professional, Sidhartha Khurana, MD, Studds Accessories, said the expansion was driven by sustained capacity pressures and rising demand across both domestic and export markets. “We were running at about 94% capacity utilisation. Anything above 90% is effectively full utilisation because you cannot operate at 100%. We could see demand building up, and that’s why this plant was planned about three years ago,” he said.

Automation-led Push

A key highlight of the upcoming facility is its automation intensity, with the company stepping up investments in robotics, connected manufacturing systems and advanced production processes.

Khurana said that around 5–10% of the total investment would be directed towards automation and related technologies. “This plant will have the highest level of automation among all our plants,” he said, adding that investments are being made across robotics, IoT integration and specialised machinery, including a fully automated paint shop.

At the same time, he noted that certain areas such as stitching, graphics application and assembly remain difficult to fully automate, prompting a hybrid manufacturing approach.

Export-led Capacity Expansion

The new plant is expected to support both domestic and export demand, although initial production could tilt towards overseas markets, where growth has been stronger. “Manufacturing is fungible. The same plant can cater to both domestic and export markets. At the moment, exports are growing faster, so initial focus could be there,” Khurana said.

The company has been witnessing steady export growth, supported by its premium brand SMK, which is targeted at international markets.

Centralised Manufacturing Strategy

Despite expanding capacity, Studds continues to maintain a concentrated manufacturing footprint in the Faridabad region, diverging from the multi-location strategy typically seen in the automotive sector.

Khurana attributed this to the complexity of the company’s product portfolio, which spans tens of thousands of SKUs across multiple models, making replication across geographies capital-intensive. “Centralisation allows us flexibility and speed. Replicating the same ecosystem elsewhere would require similar levels of investment,” he said.