Hindalco Industries, the world’s largest aluminum rolling and recycling company and an arm of the Aditya Birla Group, plans to significantly expand its manufacturing capacity of fine-quality aluminum foil that is used in rechargeable batteries for electric vehicles (EVs) and energy storage systems. The company is investing INR 800 crore ($96 million) to build a new plant near Sambalpur in Odisha that will initially produce 25,000 tonnes of the foils for Lithium-ion and Sodium-ion cells.
The factory will be located alongside a 25 MW solar power plant. It is scheduled for commissioning in July 2025 and will supplement Hindalco’s existing facility at Mouda in Maharashtra.
By 2030, the demand for battery-grade aluminum foil in India is expected to grow manifold to 40,000 tonnes, primarily driven by mushrooming growth in gigafactories for advanced cell manufacturing.
“We are seeing a fast traction in battery materials demand, driven by an impressive outlook for the electric vehicle and grid storage sectors. Raw material localization is critical in such strategic sectors,” said Satish Pai, managing director, Hindalco Industries. “Hindalco is thus making various investments in battery materials and technologies towards building Atmanirbhar Bharat [self-reliant India]. Investment in this new battery foil mill is another such step in this direction.”
Hindalco already manufactures fine-quality battery foils at its Mouda unit in Maharashtra. The Mouda unit is currently in the process of qualifying with Lithium-ion cell manufacturers in India, Europe, and the United States.
The new unit in Odisha will further augment Hindalco’s capability to supply material to Gigafactories across the world.
High-performance aluminium foils are used by cell makers as a current collector for the cathode materials. “Hindalco’s deep understanding of metallurgy, extensive experience in sheet and foil rolling and access to its own aluminium metal gives it a formidable launch pad. The company is already developing such foils to raise the bar on mechanical strength, fine-tune the thickness and enhance surface characteristics of these advanced application foils. It is working on new coatings on the battery foils that will boost performance by delivering better adhesion, lower resistance, and reduced corrosion. It will tap its robust R&D to provide tailor-made solutions for its customers,” stated Hindalco.
Hindalco is also working closely with original equipment manufacturers (OEM) to co-develop and make critical components like battery enclosures, motor housings, busbars, structural and safety components, and lightweight load bodies, many of which are being designed and developed for the first time in India.
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