Hindalco Industries Ltd., the metals flagship of the Aditya Birla Group and one of the world’s largest aluminum companies, unveiled its state-of-the-art dedicated electric vehicle (EV) component manufacturing facility in Chakan, Pune, India. At the site, the company successfully manufactured and delivered 10,000 aluminum battery enclosures to Mahindra Electric for use in the automaker’s electric SUVs — the BE 6 and XEV 9e. This marks a significant milestone in India’s clean mobility journey and accelerates the electrification of India’s automotive industry.
“Mahindra is excited to partner with Hindalco in the creation of the EV journey,” said Mr. Rajesh Jejurikar, executive director and CEO (Auto and Farm Sector), Mahindra. “Their expertise in developing materials and strong engineering capabilities to offer new solutions have played a key role in developing efficient and sustainable battery enclosure solutions. We believe this will play a transformative role in shaping the future of mobility, delivering cutting-edge solutions that will accelerate electrification in the sector.”
The battery enclosures were co-developed by Mahindra and Hindalco, with a design that offers up to 40% weight reduction over traditional steel designs. This enables an 8–10% improvement in the vehicle’s driving range, enhanced crash safety, and significantly improved thermal management for battery cooling. Additionally, these enclosures also use low-carbon aluminum, underscoring Hindalco’s commitment to sustainability and innovation. As of today, over 3,000 Mahindra EVs using these aluminum battery packs are already on Indian roads.
New EV Component Facility
The battery enclosures for Mahindra are being manufactured at the new Chakan facility, which was built with a capital investment of ₹ 500 crores and spread across 5 acres within an industrial park. The facility represents Hindalco’s first foray into EV component manufacturing and is designed to cater to the growing demand for lightweight, crash-resistant battery solutions — reinforcing the company’s commitment to innovation and sustainable mobility. It currently has the capacity to produce 80,000 enclosures annually, with plans to scale up to 160,000 units.
“Our Chakan facility represents a strategic shift in India’s EV ecosystem from import dependence to high-performance, localized aluminium solutions,” said Satish Pai, managing director, Hindalco Industries Ltd. “We are proud to partner with Mahindra in this journey, which not only reflects our commitment to the mobility transition but also highlights Mahindra’s leadership in driving the electrification of mobility in India. With our engineering strengths and sustainability focus, we are well-positioned to co-create the next generation of automotive solutions.”
The facility is expected to generate up to 1,000 jobs and aligns strongly with the India government’s “Make in India” vision to reduce dependence on imports. Another key highlight of the plant is its gender-diverse workforce, with nearly 100% women machine operators — a rarity in the manufacturing sector — demonstrating the company’s strong commitment to inclusivity.
With this milestone, Hindalco plans to scale similar capabilities for other Indian and global OEMs, expanding its aluminum offerings to include structural and crash-relevant parts for both EVs and internal combustion engine (ICE) vehicles. As India’s EV value chain matures, the demand for battery-grade aluminum and associated components is expected to surge, driven by the rapid growth of giga-factories and localized cell manufacturing. Hindalco’s investment in future-focused capabilities is a strategic move to stay ahead of this curve.