Hindalco’s greenfield plant in Belagavi, Karnataka, marks a new step in India’s advanced manufacturing capacity.
The company commissioned the facility on August 27 to produce Superfine Precipitated Aluminium Trihydrate (PPT ATH). These are materials used in halogen-free flame-retardant cables and other fire safety applications.
The greenfield plant has an initial annual capacity of 30,000 tons. Hindalco can expand the facility to 60,000 tonnes in phases.
The project brings domestic production of this material to India for the first time. It also operates entirely on renewable energy, using biomass, solar and wind power for production.
Hindalco’s greenfield plant introduces domestic production of Superfine PPT ATH, a high-value material used in Halogen-Free Flame Retardant (HFFR) cables. The material also serves polymer insulators, thermal insulation, composites and paints. In cable applications, PPT ATH helps suppress flame propagation and smoke generation without releasing halogen acid gases.
The facility has an initial production capacity of 30,000 tonnes per year. Hindalco has designed the greenfield plant for phased expansion to 60,000 tonnes. The company expects the first phase to meet almost the entire domestic demand for safer cables from the wire and cable industry.
India previously depended on imports for this grade of material. The new capacity therefore gives domestic manufacturers a local source for an important fire-safety input. It also supports the country's push to build more domestic capabilities across specialized manufacturing segments.
Further, BIS has introduced IS 17048:2018 for HFFR cables, aligning Indian standards with global safety benchmarks and supporting wider adoption across infrastructure, electrical, and mobility sectors.
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The greenfield plant also brings a sustainability element to Hindalco’s manufacturing expansion. The facility operates entirely on renewable energy from biomass, solar and wind sources. Hindalco describes the Belagavi operation as the world's only specialty alumina plant operating fully on renewable energy.
Satish Pai, Managing Director, Hindalco Industries, said, “The commissioning of our Superfine precipitated hydrate plant in Belagavi will further strengthen our leadership position and enhance our high-value specialty alumina portfolio in India. This investment reflects Hindalco’s focus on creating value, moving up the value chain and delivering advanced solutions that meet the emerging needs of customers in India and global markets.”The parent Belagavi refinery recorded greenhouse-gas intensity of 0.44 tons of COâ‚‚ equivalent per ton of alumina on a year-to-date basis in FY26. The new facility also uses automated controls for critical processes. These systems help maintain feedstock quality and product consistency during production.
Demand for fire-retardant materials continues to grow alongside stricter safety requirements, electric vehicle adoption, and infrastructure development. PPT ATH supports HFFR cables and other applications where manufacturers need flame resistance without halogen-based emissions. The Bureau of Indian Standards has also introduced IS 17048:2018 for HFFR cables, aligning Indian standards with global safety benchmarks.
Hindalco developed the technology and product through an in-house R&D process. The company describes this as a “flask-to-factory” innovation journey. The greenfield plant therefore combines new manufacturing capacity with technology developed within the company.
Saurabh Khedekar, CEO, Alumina Business, Hindalco Industries, said, “The addition of Superfine PPT ATH strengthens our Specialty Alumina portfolio and reinforces our focus on innovation-led growth. Our InnoSafe solution enhances fire safety by retarding flame spread and suppressing smoke, enabling safer and more sustainable infrastructure. As India’s first manufacturer of Superfine Precipitated Hydrate, we are proud to offer an indigenous, world-class solution that strengthens self-reliance, reduces import dependence and supports the evolving needs of the wire and cable industry.”
The commissioning also fits Hindalco’s wider move toward value-added products. The company already produces more than 120 grades of non-metallurgical specialty alumina for industries including refractories, ceramics and electronics. The new capacity adds another specialized product to that portfolio.
Hindalco Industries Limited is the metals flagship company of the Aditya Birla Group. A $31 billion metals powerhouse, Hindalco is the world’s largest aluminium company by revenues, and the world’s second largest Copper rods manufacturer (outside China).
Hindalco is India's leading producer of Specialty Alumina, manufacturing more than 120 grades of non-metallurgical specialty alumina. Its portfolio serves a wide range of industries, including refractories, ceramics, wire and cable, railways, batteries and electronics, water treatment, and bulk chemicals.
Engineered to deliver critical performance attributes such as flame retardancy, thermal management, electrical insulation, strength, and durability, these products support more than 1,000 customers across 42 countries. Hindalco's specialty alumina enhances fire safety in applications ranging from Vande Bharat trains to advanced power and communication cables, while other specialized grades are used in the manufacture of display glass for smartphones and other electronic devices. The addition of Superfine PPT ATH further expands this portfolio into advanced flame-retardant applications.
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