BALCO Set to Enter the Million Tonne Club Powering India’s Aluminium Self-Reliance

First metal produced from India’s largest 525 kA Smelter Growth Project; poised to capture over 1/5th of India’s aluminium market share

Shabdawani Samachar, 13 October 2025, (Managing Editor Mr. Ashok Lalwani 8803818844), Balconagar. Bharat Aluminium Company Limited (BALCO), India’s iconic Aluminium producer and a part of Vedanta Aluminium, has achieved a landmark in India’s aluminium industry by producing the first metal from the nation’s largest 525 kilo Ampere (kA) smelter under its ongoing 1 million tonne per annum (MTPA) expansion project. This technological advancement surpasses the earlier national benchmark of 378 kA, setting new standards in scale, efficiency, and operational excellence. With the commissioning of the new 0.435 MTPA potline, BALCO’s total aluminium production capacity will reach 1 MTPA, placing the company among the select global producers in the Million Tonne Club. This expansion supports the Government of India’s ‘Make in India’ vision and advances the nation’s self-reliance by ensuring greater availability of domestically produced, high-quality aluminium for critical sectors such as defence, aerospace, automotive, construction, and power transmission. With the ramp-up, BALCO will contribute over 20% of India’s total aluminium production, positioning itself at the forefront of the nation’s industrial progress. This milestone is made possible through close collaboration with leading global and domestic partners, including Larsen & Toubro (L&T), Asea Brown Boveri (ABB), Siemens, and Guiyang Aluminium Magnesium Design & Research Institute Co., Ltd (GAMI), who have brought in advanced engineering, automation, and efficiency-driven systems.

Speaking on the expansion, Mr. Rajesh Kumar, CEO & Director, BALCO, said With our entry into the Million Tonne Club, BALCO is scripting a new chapter in India’s journey of self-reliance. Aluminium is a metal of national importance, with applications spanning strategic sectors and everyday life. Through this expansion, we are not only boosting domestic capacity but also generating new avenues of employment, spurring allied industries, and driving economic growth in Chhattisgarh and beyond reinforcing our committed to nation building with responsibility, efficiency, and innovation. In parallel, BALCO is expanding its downstream capabilities to meet India’s rising demand for advanced aluminium applications. The company has modernized and expanded its Rolled Product facility to 1.8 lakh tonne per annum (LTPA) to meet the specialized requirements across critical industries. Additionally, a new 50 kTPA wire rod line has been commissioned, enhancing BALCO’s total wire rod capacity to 2.3 LTPA. These investments will broaden the company’s value-added product portfolio and improve India’s manufacturing competitiveness.

With BALCO’s capacity expansion to 1 MTPA, Vedanta Aluminium will scale up to 2.8 MTPA, positioning it as the world’s largest aluminium producer and a key enabler of India’s industrial self-reliance. By leveraging technology leadership, process efficiency, and operational excellence, the company is setting new industry benchmarks in productivity and sustainability. The adoption of advanced smelting technology is expected to drive substantial energy efficiency gains, underscoring company’s commitment to responsible growth.