Hindalco’s Odisha expansion signals the next phase of India’s manufacturing boom

The company unveiled a ₹21,000-crore smelter expansion at its Aditya Aluminium complex in Sambalpur, adding 3.6 lakh tonnes per annum (LTPA) of capacity, and commissioned a 1.7 LTPA Flat Rolled Products (FRP) and battery-grade aluminium foil manufacturing facility with an investment of ₹4,500 crore.

The projects were inaugurated by the Hon’ble Chief Minister of Odisha, Shri Mohan Charan Majhi.

A major milestone in India’s clean-energy journey, the battery-grade aluminium foil facility—the first of its kind in the country—is designed to support up to 100 GWh of lithium-ion cell manufacturing capacity. Drawing input directly from the FRP complex, the facility strengthens domestic capabilities in critical raw materials for electric mobility and energy storage.

These investments form part of Hindalco’s broader growth capital expenditure programme, with around ₹37,000 crore planned for Odisha across upstream and downstream aluminium operations. The Odisha investments constitute a significant portion of the company’s ₹55,000-crore growth capex planned across India.

Hindalco is India’s largest flat-rolled products manufacturer, accounting for over 50% of the domestic market. With nearly 40% of flat-rolled aluminium currently imported, the expanded FRP capacity is expected to reduce import dependence by almost half, boosting domestic manufacturing and enhancing India’s global competitiveness in high-grade aluminium products.

The smelter expansion at Aditya Aluminium also marks a step forward in energy transition, with a portion of its power requirements planned to be met through round-the-clock renewable energy (RE-RTC), embedding sustainability into large-scale industrial growth.

Commenting on the development, Kumar Mangalam Birla, Chairman, Aditya Birla Group, said, “India’s manufacturing growth depends on integration, value addition and sustainability. Through Hindalco, we are building a fully integrated aluminium ecosystem—from upstream resources to high-value downstream products. Our long-standing partnership with Odisha continues to play a vital role in this journey. This strategy strengthens India’s self-reliance, supports critical sectors and accelerates the transition towards advanced, sustainable manufacturing.”

Satish Pai, Managing Director, Hindalco Industries Ltd, said, “The FRP expansion and smelter growth at Sambalpur exemplify our integrated upstream-downstream growth strategy. This enables Hindalco to deliver high-quality aluminium solutions across packaging, defence, electric mobility, renewable energy and advanced manufacturing, while creating long-term value.”

Hindalco’s presence in Odisha spans over 15 years of partnership with the State, during which it has invested more than ₹25,000 crore across bauxite mining, alumina refining, primary aluminium smelting and downstream manufacturing.

The company’s integrated operations link upstream resources—bauxite, alumina and primary aluminium—with high-value downstream products such as FRP and battery foil, creating a robust, end-to-end aluminium ecosystem.

Currently employing nearly 23,000 people, Hindalco’s Odisha operations are expected to generate over 15,000 additional direct and indirect jobs in the next phase.

The broader investment pipeline includes the FRP and battery foil facilities, the primary aluminium smelter expansion, Kansariguda alumina refinery, Meenakshi coal mine, specialised materials such as white fused alumina, and ancillary manufacturing units—further consolidating Odisha’s status as a national hub for aluminium excellence.

Sustainability underpins Hindalco’s growth strategy, with downstream manufacturing delivering lower carbon intensity per tonne, supported by renewable energy integration, advanced technologies and responsible resource management. Through CSR initiatives spanning education, healthcare, skill development and women’s empowerment, the company continues to ensure its industrial growth translates into inclusive and sustainable development.