Steelbird Hi-Tech Scales Up In-House Manufacturing, Targets 60,000 Helmets/Day with New Carbon Fiber Line
Aims for ₹1,300 Cr Turnover by FY 2026-27; Plans India’s First In-House Carbon Fiber & Fiberglass Weaving Facility
Steelbird Hi-Tech India Ltd., one of the world’s leading helmet manufacturers, is significantly expanding its in-house production capacity and technological capabilities as it prepares to produce over 60,000 helmets per day. Backed by an aggressive expansion strategy and major infrastructure upgrades, Steelbird is positioning itself at the forefront of innovation in the Indian and global helmet industry.
After completing a ₹54 crore capex in the previous fiscal, Steelbird is investing another ₹50 crore this year to upgrade and expand its plants and machinery. The result: a total installed daily capacity exceeding 60,000 helmets — a milestone that aligns with the brand’s steadfast commitment to quality and self-reliance.
With six state-of-the-art plants in Baddi, three in Noida, and operations spread across over 1 million sq. ft., Steelbird maintains complete control over its production. From shells, EPS, visors, buckles, to decals and carry bags — every critical safety component is made in-house, eliminating reliance on third-party vendors and job workers.
Steelbird’s EPS facility alone spans 7,500 sq. m. and produces 45,000 EPS units daily, along with EPP capabilities. Its dedicated decal plant churns out 14,000 decals per day. Over ₹40 crore has been invested into building infrastructure for EPS, EPP, and decals, reinforcing Steelbird’s mission of zero compromise on safety.
India’s First In-House Carbon Fiber & Fiberglass Weaving Facility
Steelbird is now eyeing the next frontier — a fully integrated carbon fiber helmet manufacturing unit. The facility will include India’s first in-house carbon fiber and fiberglass weaving plant, allowing Steelbird to control material strength, flexibility, and impact resistance at the source. The company aims to engineer ultra-lightweight, high-strength helmet shells using hybrid material combinations and advanced weaves.
“Every helmet component at Steelbird is made in-house to maintain the highest safety standards,” said Rajeev Kapur, Managing Director, Steelbird Hi-Tech India Ltd. “We do not rely on third parties because even the slightest deviation in specs can compromise lives. For us, quality is non-negotiable.”
Innovation-Driven Roadmap
In response to growing consumer demand for smarter, safer, and more stylish helmets, Steelbird is expanding its product portfolio. FY 2025 will see the launch of 15 new helmet models, with 10 new models planned for each following year. Development of a new helmet can cost anywhere between ₹1.5 crore to ₹10 crore and typically spans 2–3 years, depending on complexity and feature integration.
Steelbird’s strategic focus is on smart features, wearable tech, lightweight materials, and design-led aesthetics, as helmets evolve from pure safety gear to lifestyle and tech products.
Revenue Growth Trajectory
Steelbird closed FY 2023-24 with a group turnover of ₹787 crore. For FY 2024-25, the company is targeting over ₹1,000 crore in revenue, driven by the production and sale of over 10 million helmets. By FY 2026-27, the goal is to cross ₹1,300 crore.
With rising awareness around helmet safety and the government’s push for stricter enforcement, Steelbird is leveraging its in-house manufacturing prowess, technological innovation, and design excellence to stay ahead in the rapidly evolving two-wheeler accessories market, not just in India but globally.
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