On the sidelines of Hindalco’s new branding unveil in Mumbai, Rajesh Rajgor sat down with Satish Pai, Managing Director, and Nilesh Koul, Senior President, CEO, Downstream, Aluminium, Hindalco Industries Ltd., for an exclusive interview. The discussion revolved around Hindalco’s evolution from a materials supplier to an innovation-driven solutions provider, with a strong focus on electric mobility, renewable energy, battery materials, and sustainable recycling initiatives.
“This marks a pivotal moment as we transition from a metals manufacturer to a solutions provider. Our new identity, ENGINEERING BETTER FUTURES, reflects our commitment to Sustainability, Circularity, Durability, and Precision Engineering,” said Satish Pai, Managing Director Hindalco Industries Ltd. Recognized for five consecutive years as the World’s Most Sustainable Aluminium Company in the S&P Global CSA rankings, Hindalco continues to push energy efficiency and eco-friendly production. Chairman Kumar Mangalam Birla announced a ₹45,000 crore investment across aluminium, copper, and specialty alumina businesses, reinforcing Hindalco’s role as a catalyst for change in India’s industrial landscape.
Hindalco is actively driving advancements in EVs, packaging, and battery technologies, supplying specialized aluminium and copper components. It has played a key role in ISRO’s Chandrayaan and Mangalyaan missions. Sustainability remains a top priority for the company, with India’s first e-waste recycling plant by Birla Copper and a 100MW renewable energy project in Odisha, integrating wind, solar, and hydro storage.
Revolutionizing Transport, Sustainability, and Infrastructure
Hindalco’s transition is evident in its approach to emerging industries. A prime example is the development of aluminium castings for lithium-ion electric vehicle batteries, enhancing protection and safety. “We are working with our customers on battery enclosures and protective aluminium cells while also supplying aluminium and copper foils to battery manufacturers setting up in India,” explains Satish. The goal is to become a crucial partner in India’s growing EV ecosystem.
The commercial vehicle sector is another focus, where aluminium is driving efficiency, reducing emissions, and enabling electrification. Hindalco is developing lightweighting solutions, such as aluminium-based vehicle chassis and last-mile delivery containers. “Lightweighting increases vehicle efficiency and payload capacity, directly benefiting commercial operators,” he notes. Aluminium’s versatility makes it indispensable in the shift towards sustainable transport solutions.
Sustainability remains at the core of Hindalco’s strategy, leveraging aluminium’s infinite recyclability. “We are also setting up facilities to extract valuable metals like copper and rare earths from electronic waste, reinforcing our commitment to urban mining and sustainability,” Satish highlights. Beyond EVs and sustainability, Hindalco is expanding across industries, including construction, power, and defence. “We aim to contribute to India’s infrastructure growth, supporting affordable housing, renewable energy, and hybrid energy solutions,” he adds.
Hindalco is also innovating in railways, pioneering India’s first all-aluminium coal transportation rake, which offers lower maintenance costs and a 20% increase in carrying capacity. “We are collaborating with the government to introduce aluminium-bodied high-speed trains and metro coaches, aligning with global best practices in railway modernization,” Satish states.
Hindalco’s Engineering Shift
As Hindalco repositions itself as an engineering and solutions-driven enterprise, it is set to play a pivotal role in India’s industrial transformation. “The opportunity for our aluminium and copper solutions is significantly higher in the EV segment, and we are actively working with partners to develop new solutions,” says Nilesh Koul. One of the biggest growth drivers is battery materials, particularly aluminium foil and copper foil separators, which are crucial for cell manufacturing. “With new cell capacities coming up in India, the demand for domestically produced battery materials is set to rise sharply. We are investing over ₹800 crore in a dedicated battery foil capacity in Odisha,” he adds.
Hindalco has forged deep collaborations with OEMs in the EV space, engaging from the design phase to production. “We have a dedicated plant in Chakan, Pune, for manufacturing electric battery enclosures for one of India’s largest EV makers,” he reveals. In the two-wheeler segment, Hindalco is a major supplier of battery casings for swappable batteries, working closely with brands like Hero Vida. Beyond battery enclosures, the company is innovating in crash systems, motor casings, and precision-engineered extrusions that enhance performance, safety, and aerodynamics.
Innovating Mobility: Advanced Alloys & Lightweight Solutions
A key example of Hindalco’s R&D efforts is in motor casing development. “Traditional casting-based enclosures had thermal efficiency challenges, so we are developing extrusion-based solutions that offer superior performance,” says Nilesh. Additionally, the company has introduced unique alloys for EV bus bars that improve connectivity and safety. To drive these innovations, Hindalco has strengthened its talent pool by hiring industry experts in engineering, design, welding, and machining. “We have invested significantly in attracting top talent and building our teams to ensure cutting-edge solutions,” he asserts.
Automotive remains one of Hindalco’s largest and fastest-growing segments, spanning applications from primary foundry alloys for wheels to copper wire harnesses. “We expect the segment to grow by 14-15% over the next few years, and we will continue expanding our facilities to support this growth,” he notes. Railways, though a separate division, also benefits from aluminium solutions, with Hindalco having introduced India’s first aluminium wagon rig, which is 20% lighter and more efficient.
Summing up Hindalco’s commitment to the automotive sector, he affirms, “We are dedicated to working with OEMs to deliver high-performance, sustainable solutions. Our focus is on innovation, efficiency, and quality while ensuring affordability and value for Indian customers and the economy.”
