#### **Overview** Hindalco Industries Limited, part of the Aditya Birla Group, is India’s largest fully integrated aluminium producer and a global leader in non-ferrous metals. Through its 100% subsidiary **Novelis**, Hindalco is also the **world’s largest producer of flat-rolled aluminium and aluminium recycler**. The company operates across **aluminium, copper, and specialty alumina** segments with a vertically integrated value chain from mining to high-value downstream fabrication. Hindalco’s global footprint spans **50+ manufacturing units across 10 countries**, including 17 mines in India and 33+ overseas plants via Novelis. With a workforce of over 23,000 employees, the company has transformed from a traditional metal manufacturer into a **value-added, innovation-driven solutions provider**, aligned with megatrends such as electrification, decarbonization, and digitalization. --- #### **Growth Strategy & Financial Vision** - **Downstream EBITDA Goal:** Target to **quadruple downstream EBITDA by FY30** (from FY24 base), driven by expansion in **value-added, high-margin products**. - **$10 Billion Global Investment Plan (2025–2030):** Allocated across India and Novelis for expansion in **aluminium, copper, and specialty alumina**, with a focus on **resource security, circular economy, and low-carbon manufacturing**. - **Strategic Pillars:** Sustainability, Digitalisation, and Culture. - **Revenue Drivers:** Value-added products, import substitution, recycling, and localization to mitigate exposure to LME price volatility. --- #### **Upstream Expansion & Resource Security** Hindalco is aggressively scaling **upstream capacity** to secure raw materials and strengthen first-quartile cost leadership: - **Alumina & Smelting:** - **Greenfield 850 KTPA alumina refinery (Aditya, Odisha):** Scheduled for FY26–27. **India’s first alumina refinery powered by 24/7 renewable energy**. - **Smelter expansions:** +180 KTPA at Aditya and +360 KTPA at Mahan. The **400 kA Booster Section Project** aims to enhance smelting efficiency and reduce energy consumption. - **Coal Mining:** - **Meenakshi (12 MTPA, Odisha)** and **Chakla (4.5 MTPA, Jharkhand)** mines under development to reduce coal imports and support low-cost production. - **Backward Integration:** A **definitive agreement with Orissa Mining Corporation (OMC)** ensures long-term bauxite availability for the new refinery. --- #### **Downstream & Value-Added Product Expansion** The company is shifting focus to **high-growth, high-margin downstream products** in sectors like EVs, renewables, defence, and smart infrastructure: ##### **Aluminium Downstream Projects (India):** - **Flat Rolled Products (FRP):** 170 KTPA expansion in Aditya (Odisha), increasing downstream capacity to **600 KTPA**, with potential for **800 KTPA**. - **Battery Foils & Enclosures:** - **24 KTPA battery foil mill (Aditya):** Supports EV and energy storage demand. - **Automated robotics plant (Chakan, Pune):** Produces **all-aluminium EV battery enclosures**; annual capacity of **164,000 units**. - **EV Lightweighting:** - India’s first **aluminium propeller shaft for 4W EVs (56% lighter)**. - Co-developed **crash management systems, motor housings, and trailers** with OEMs. - **Building & Construction:** - **Eternia & Totalis:** B2C brands for **windows, façades, and modular kitchens**; present across **100+ channel partners**. - Launched **Duranium® alloy** for high-strength, dent-resistant fenestration solutions. ##### **Copper Business:** - **Dahej Expansion:** Brownfield project to increase **refined copper capacity to 721 KTPA**, making it the **largest copper smelter outside China**. - **India’s First Copper & E-Waste Recycling Plant (Pakhajan, Gujarat):** Initial 50 KTPA (scalable to 200 KTPA); produces **copper cathodes, gold, silver, platinum group metals**; supports EPR norms. - **New Product Lines:** - **Battery-grade copper foil (11.5 KTPA Phase I).** - **Inner Grooved Tubes (IGT) for ACs** (25 KTPA); reduces import dependence. - **Copper-magnesium/silver alloys for railways and metro systems.** ##### **Specialty Alumina (Global Top 3 Player):** - Current shipments: **>500 KTPA**, targeting **1 million KTPA in 3–5 years**. - **Key Projects:** - **60 KTPA White Fused Alumina (FUSALOX™):** For precision abrasives and advanced refractories. - **20 KTPA Precipitated Superfine Hydrate (Belagavi):** Halogen-free flame retardant. - **Low-soda Boehmite:** For lithium-ion battery separators. - **Acquisition of AluChem (US):** $125 million deal; provides access to **low-soda tabular alumina** and strengthens North American footprint. --- #### **Novelis Global Projects: $4.1 Billion Bay Minette & Beyond** Via its subsidiary **Novelis**, Hindalco is redefining the global aluminium landscape: - **Bay Minette, Alabama (USA):** - **$4.1 billion greenfield rolling & recycling plant.** - Capacity: **600 KTPA flat-rolled products** (420 KTPA for beverage cans, 180 KTPA for automotive). - **All beverage capacity pre-contracted** with Coca-Cola, Ball Corp., Ardagh. - Expected commissioning: **second half of 2026**. - Will make Novelis' total capacity **~5 million tonnes/year**. - **Recycling & Sustainability:** - **$365M advanced recycling center (Guthrie, KY):** 240 KTPA capacity; reduces emissions by **>1 million tonnes CO₂/year**. - **$90M expansion (Latchford, UK):** Doubles used can recycling capacity. - Target: **75% recycled content in products by 2030** (vs 63% in FY24). - **31 plants globally with recycling capabilities**; **91% of input materials recycled** (including 82 billion used beverage cans in FY24). - **3x30 Vision:** - ↑ Recycled content: **63% → 75%**. - ↓ Carbon footprint: **4 → 3 tonnes CO₂ per tonne of product**. - Maintain **high ROIC**. - **Automotive Innovations:** - Second-gen **aluminium EV battery enclosures** (lighter, higher energy density). - Partnership with OEMs on **full aluminium-intensive vehicles (AIV)**. - Supplied **friction stir welded fuselage demo** for aircraft, saving **7 tonnes CO₂/year**. --- #### **R&D & Innovation** Hindalco fosters a **technology-first, innovation-led culture**: - **8 Global R&D Hubs:** Kennesaw (US), Spokane (US), Stuttgart (Germany), Sierre (Switzerland), Shanghai (China), etc. - **Hindalco Innovation Centres (HIC):** In Belagavi, Taloja, Dahej, and Mahan. - **Collaborations:** IITs, CSIR, Fraunhofer, Gefertec, ABSTCPL. - **Recent Innovations:** - **Digital Twin Technology:** Reduced anode rejection rates by 24%. - **AI-based Cathode Classification:** Cut defects by 33% in copper refining. - **Coil Allocation Module (CAM):** AI-driven system to optimize quality and reduce rejections. - **Carbon Black Primer Coating (for Li-ion battery foils):** Improves fast-charging performance. - **Proprietary HIL1X-HC alloy** with high strength and conductivity for battery applications. --- #### **Sustainability & Digital Transformation** - **Circular Economy Champion:** - Recycles **e-waste, used beverage cans, post-consumer scrap**. - Uses **100% of bauxite residue in cement**. - **Decarbonisation:** - **Round-the-clock (RTC) renewable power** for smelting via Greenko. - Target: **30% low-carbon aluminium** within 3–4 years. - Aligns with EU CBAM and ESG norms. - **Digital Integration:** - **AI, Industrial IoT, machine learning, digital twins** deployed in smelting, quality control, and logistics. - Over **1,500 employees trained** in data analytics and Generative AI.