### **Overview** Balu Forge Industries Ltd (BFIL), incorporated in 1989 by Late Mr. Prehlad Singh Chandock, is a leading Indian precision engineering company specializing in the manufacture of **forged and precision-machined components** for global OEMs. The company was restructured through a **reverse merger with Amaze Entertech Limited in August 2020** and is now a publicly listed entity. BFIL serves a diverse range of high-value industrial sectors including **Automotive, Aerospace, Defence, Railways, Power Generation, Oil & Gas, and New Energy Mobility (NEV)**. With over **35 years of industry experience**, BFIL has evolved from a traditional forging player into a globally competitive, end-to-end precision engineering solutions provider. The company has significantly diversified its business model and customer base, now operating **four fully integrated manufacturing facilities** across India and the UAE. --- ### **Core Business & Capabilities** - **Products & Applications**: - Crankshafts, transmission shafts, brake components, hydraulic motors, turbine blades, axles, railway wheels, wheel sets, undercarriage parts, oil & gas flow components, and engine parts. - Components range from **1 kg to 1,500 kg** and up to **3 meters in length**, supporting both **internal combustion engine (ICE)** and **New Energy Vehicle (NEV)** platforms. - **Manufacturing Infrastructure**: - **Four integrated facilities**: two in Kakti, Belgaum (Karnataka), a new **greenfield campus in Hattargi, Belgaum (46+ acres)**, and one in **Ras Al Khaimah, UAE**. - Capabilities include **forging, heat treatment, precision machining, assembly, and testing**, with full backward integration. - Equipped with: - **8,000-ton mechanical press**, **25T, 16T, and 10T hydraulic hammers**. - **CNC, 7-axis and 11-axis machines**, **Junker CBN grinders**, and **robotic handling systems**. - **GERB anti-vibration technology**, reducing vibration by up to 90%, enhancing precision and equipment lifecycle. - **Industry 4.0-compliant smart manufacturing**, leveraging IoT, machine learning, and real-time monitoring. - **Capacity** (as of Nov 2025): - **Forging Capacity**: Over **122,000 MTPA**, with plans to scale to **150,000 MTPA**. - **Machining Capacity**: Over **45,000 MTPA**, with ongoing expansion. - **Railway Production**: Capacity to produce **6,000 wheel sets per year**, suitable for multiple gauges, serving Indian Railways and international clients, including a Middle Eastern nation. --- ### **Strategic Expansion & Investments** - **Greenfield Campus (Hattargi, Belgaum)**: - A **46+ acre advanced manufacturing hub** under development, featuring: - Fully automated, Industry 4.0-compliant production lines. - Dedicated **defence forging and machining line**, with focus on **artillery, armoured vehicles, and engine components**. - **Solar farm** for sustainable energy, supporting ESG goals. - Expected to be fully operational in **H1 FY26**, targeting a **captive forging capacity of 150,000 MTPA** and **machining capacity above 80,000 MTPA**. - **Acquisitions & Technology Enhancements**: - **Mercedes-Benz Truck AG (Germany, 2021)**: Acquisition of a **precision machining unit** enabled BFIL to become a supplier for Class 7 & 8 trucks, boosting high-margin product offerings. - **Thyssenkrupp AG (France, 2010)** and **Ursus SA (Poland, 2006)**: Strategic asset acquisitions that expanded international manufacturing footprint and production scale. - **7-Axis & 11-Axis CNC Machines**: Enable production of complex components for aerospace, defence, and rail sectors in a single setup. - **Additive Manufacturing (3D Printing)**: Used for rapid prototyping and tooling, supporting innovations in new materials and complex geometries. - **Joint Ventures & Partnerships**: - Signed an **MoU with Swan Energy Limited** to form a **Special Purpose Vehicle (SPV)** targeting **defence, aerospace, railways, and nuclear sectors**. The joint venture is now active as of Feb 2025. --- ### **Market Presence & Customer Base** - **Global Reach**: - Serves clients in **over 80 countries** across six continents. - Maintains **long-term vendor approvals** with **25+ global OEMs**. - **Exports contribute ~73–99% of total revenue**, with strong presence in **Europe, North America, Asia, Africa, and the Middle East**. - Operates through **three subsidiaries**: Safa Otomotiv FZ LLC (UAE), Kelmarsh Technologies FZ LLC (UAE), and Naya Energy Works Pvt Ltd (India). - **Industry Exposure**: - **Three Key Segments**: 1. **Automotive Components** – Largest revenue contributor. 2. **Industrial & Agricultural Components** – Growing due to infrastructure and mechanization trends. 3. **New Energy & E-Mobility** – High-growth focus area. - Serves critical sectors: - **Defence**: Over **180 approved components** including shell casings, gear rings, and undercarriage parts. Supplier to **two European defence forces** on an exclusive basis. - **Railways**: One of the **few fully integrated suppliers** of wheel-axle-wheelset combinations globally. - **Aerospace & Oil & Gas**: Produces high-tolerance valve bodies, turbine blades, landing gear, and pump components. --- ### **R&D & Innovation** - **Dedicated R&D Team**: Over **75 professionals** (up from ~45 in 2023), focused on: - **Advanced materials**: Aluminum, titanium, magnesium, and high-strength alloy development. - **New product development**: For EVs, hydrogen vehicles, and defence systems. - **Process optimization**: Additive manufacturing, 4–11 axis machining, ultrasonic and high-speed grinding. - **Sustainability**: Low-CO₂ refining (**NayaRefine**), battery recycling, second-life applications for spent batteries. - **Innovation Centers**: - **8,000 sq. m R&D and Innovation Campus (Belgaum)** under construction, housing: - Naya Energy Works R&D division. - Focus on **fuel cell development, cylindrical cell (LFP/NMC)**, **metal-air batteries**, **advanced composites**, **new energy powertrains**, and **advanced defence systems**. - Active in **rapid prototyping**, **finite element analysis (FEA)**, **fatigue testing**, and **digital twin simulations**. --- ### **New Energy & E-Mobility Initiatives** - **Naya Energy Works (Subsidiary)**: - Focus on **electric motors (BLDC, PMSM, ACIM, Axial Flux)**, **battery technology**, **hydrogen fueling stations**, **charging infrastructure**, and **battery recycling**. - Launch of **Plug & Play Modular Battery System (MBS)** for two-wheelers (60–240 km range) with **swappable batteries**. - Developing **ultra-fast chargers (up to 1.2 MW)** and **wireless charging stations** for commercial EVs. - **NEV Product Portfolio**: - Rotor carriers, main drive shafts, eccentric shafts for **electric and hybrid vehicles**. - Lightweight aluminum forgings for EVs. - Hydrogen compressor components and fuel-agnostic systems. --- ### **Key Milestones & Achievements** | Year | Milestone | |------|-----------| | 1989 | Founded in Belgaum, Karnataka | | 1991 | Began manufacturing first component | | 1995 | First export shipment | | 2006 | Acquired Ursus SA (Poland) manufacturing plant | | 2010 | Acquired Thyssenkrupp AG (France) facility | | 2014 | Achieved 1,000 crankshafts per day | | 2017 | Supplier to 25+ OEMs across five continents | | 2020 | Listed on stock exchange via reverse merger | | 2021 | Acquired Mercedes-Benz machining unit (Germany) | | 2023 | Greenfield Hattargi facility development begins | | 2025 | Commercialization of Empty Shell forging line (360,000 units/year), full operation of key expansions |