Bhubaneswar: Hindalco Industries, the global leader in aluminum rolling and recycling, is set to significantly increase its production capacity of high-quality aluminum foil used in rechargeable batteries. This expansion aims to meet the surging demand in the electric vehicle (EV) and energy storage systems markets. With an investment of Rs. 800 crore, the company is establishing a new facility near Sambalpur in Odisha, initially capable of producing 25,000 tonnes of this resilient product crucial for Lithium-ion and Sodium-ion cells.
Anticipating a manifold increase in demand to 40,000 tonnes by 2030, driven by the proliferation of gigafactories for advanced cell manufacturing, Hindalco is strategically positioning itself to cater to the evolving needs of the battery-grade aluminum foil sector in India.
Satish Pai, Managing Director of Hindalco Industries, emphasized the accelerated demand for battery materials, especially in the Electric Vehicle and Grid Storage sectors. He highlighted the strategic importance of localizing raw materials in these sectors, aligning with the vision of building an Atmanirbhar Bharat (self-reliant India). The investment in the new battery foil mill is a pivotal step towards achieving this objective.
Having already achieved a technological breakthrough in manufacturing high-quality battery foils at its Mouda unit in Maharashtra, Hindalco is actively qualifying with Lithium-ion cell manufacturers in India, Europe, and the United States. The upcoming unit in Odisha will further enhance the company’s capability to supply materials to Gigafactories worldwide.
Hindalco’s expertise in metallurgy, extensive experience in sheet and foil rolling, and access to aluminum metal provide a robust foundation. The company is committed to advancing the mechanical strength, thickness, and surface characteristics of these advanced application foils. Ongoing research includes developing new coatings for battery foils to improve performance by enhancing adhesion, reducing resistance, and minimizing corrosion.
This initiative aligns with the government’s green agenda to reduce carbon emissions and promote sustainable growth. Hindalco is also collaborating with original equipment manufacturers (OEM) to co-develop critical components such as battery enclosures, motor housings, busbars, structural and safety components, and lightweight load bodies. These innovations position Hindalco as a provider of high-tech metal solutions, marking a significant transformation from a mere metal manufacturer.
Scheduled for commissioning in July 2025, the new facility in Odisha will be located alongside a 25 MW solar power plant and will have access to additional solar energy through a 400 KV National Grid connection, contributing to the company’s commitment to sustainable practices.