With a legacy spanning over three decades, Balu Forge Industries Ltd. has cemented its position as a global leader in precision engineering, catering to industries such as automotive, aerospace, defence, and railways. Under the leadership of Jaikaran Chandock, Director, the company has strategically expanded its footprint through acquisitions, cutting-edge manufacturing capabilities, and a strong commitment to sustainability. As Industry 4.0, AI, and automation redefine the future of precision engineering, Balu Forge continues to innovate, ensuring its products meet the highest global standards. In this exclusive interview with Machine Edge Global, Jaikaran Chandock sheds light on the company’s evolution, its competitive edge, and its vision for the future of advanced manufacturing.
Balu Forge Industries Ltd. has a legacy of over three decades in precision engineering. How has the company evolved over the years to become a leader in advanced manufacturing technologies?
Balu Forge commenced operations in 1989 has over 3 decades of experience in the field of precision engineering. Our growth has been driven by strategic acquisitions, starting with the Ursus Manufacturing Plant from Poland in 2006 and the Thyssenkrupp Plant from France in 2010, which bolstered our early expansion. By 2011, we had established a global presence in over 80 countries, and in 2012, we earned the ISO/TS 16949:2009 certification from TÜV NORD, ensuring the highest standards of quality and safety.
A major milestone came in 2021 with the acquisition of the Precision Machining unit of the Mercedes Benz Truck Plant from Mannheim, Germany, allowing us to produce precision machined components for Class 7 and 8 trucks and heavy-duty vehicles. This expansion, along with planned capacity increases has increased our machining capacity to 32000 MTPA. There is a clear road map for further capacity expansion both in the area Forging & Machining.
Additionally, our acquisition of advanced hydraulic forging hammers and mechanical presses enhances both our product portfolio and R&D capabilities, enabling us to enter new industries. With decades of expertise in precision machining and metal forming, Balu Forge has become one of the world’s largest precision engineering companies, well-positioned for sustained growth through strategic diversification and capacity expansion. The company has also introduced advance machining capabilities through its acquisition of 7 Axis CNC machines which will further cement a strong position in industries such as aerospace, defence, railways amongst others.
With a presence across industries such as defence, aerospace, and railways, what are some of the key factors that set Balu Forge apart from its competitors?
We are strategically positioned for growth through several key initiatives:
• Expansion: We have invested in a new 52,000 sq.mt manufacturing facility in Belgaum, Karnataka which is only the 1st phase, and after the commercialization of Mercedes Benz plant our capacity has increased by 14,000 MTPA to 32,000 MTPA. Our recent acquisitions, including three forging lines, will elevate our forged capacity to 72,000 MTPA. This is however only the 1st phase as we have a total manufacturing campus of 46 Acres in the works with advanced forging & machining capacity expansion in place & clear roadmap for the next phase of growth.
• Global Reach: With 90% of products exported to over 80 countries, Balu Forge has a strong global presence, particularly in Europe, MENA, and Americas, providing stability against regional fluctuations & geopolitical issues.
• B2B Growth: As a direct supplier to OEMs and Tier 1 companies across various sectors, Balu Forge benefits from long-term partnerships that ensure a steady revenue stream.
• Industry Diversification: We serves multiple industries, including automotive, agriculture, defence, and aerospace, which mitigates risks and opens new growth avenues.
• Precision Engineering Integration: By combining precision machining with forging capabilities, our EBITDA margins will expand and we also offer value-added products to global customers.
These strategies position Balu Forge for future readiness and the ability to seize emerging opportunities in the manufacturing landscape.
The company caters to both New Emission Regulations and New Energy Vehicles. How is Balu Forge adapting to the evolving global sustainability trends in manufacturing?
In 2012, the Company got accredited with ISO/TS 16949:2009 accreditation from world renowned company TUV NORD. Achieving a TÜV certification means your company’s products have attained the requirements of safety, quality, and sustainability. This gives resellers and partners the confidence to work with you and consumers the peace of mind to use your products. The company further got accreditations for ISO 45001 & ISO 14001 in the following years.
The Company has embedded sustainability into its supply chain, mandating that suppliers adhere to stringent environmental, legal, and ethical standards. Manufacturing processes are optimized annually to minimize energy and resource consumption. The Company prioritizes locally sourced, high-quality materials and advocates for sustainable packaging practices. A comprehensive supplier sustainability code sets forth the criteria for vendor selection, emphasizing safety, health, environmental responsibility, and ISO certification.
At Balu Forge, sustainability isn’t just a requirement—it’s a responsibility we take seriously. As the industry evolves, we remain committed to innovation, ethical manufacturing, and reducing our environmental footprint. By continuously enhancing our processes and setting high standards across our supply chain, we aim to build a future where precision engineering and sustainability go hand in hand, creating long-term value for our customers, partners, and the planet. We have a dedicated team with a focus on sustainability where every carbon footprint is analysed & attempts are made to offset the same as much as possible. There is traceability in every area of the business where the impact & mitigating processes can be seen.
What role does incremental innovation play in enhancing productivity, flexibility, and speed across Balu Forge’s manufacturing plants?
Incremental innovation is at the heart of Balu Forge’s manufacturing strategy, driving continuous improvements in productivity, flexibility, and speed. By making strategic enhancements to our processes, we optimize efficiency, reduce waste, and improve precision without disrupting operations. Automation, real-time data analytics, and advanced tooling enable us to adapt quickly to evolving industry demands while maintaining high-quality standards. This agile approach ensures that our manufacturing plants remain competitive, responsive, and future-ready, delivering superior products with greater speed and reliability.
Each of our facilities are equipped with complete CNC manufacturing capabilities, an in-house tool room, and a metallurgical lab. Our fully integrated plant supports our geographically dispersed customers through every stage of the process—from concept and product design to engineering, manufacturing, testing, and validation. We are now integrating an advanced Forging & Machining production capabilities that offer a large product portfolio ranging from 1 Kg to 1000 Kgs and up to 3 Metres long. Our facility will be one of the very few that will be equipped with both closed die forging hammers and presses & advanced precision machining all under one roof.
How does Balu Forge plan to leverage India’s growing manufacturing ecosystem and the government’s push for ‘Make in India’ in sectors like defence and aerospace?
We recognize the vast potential of India’s rapidly evolving manufacturing ecosystem and the government’s strong push for ‘Make in India,’ particularly in high-value sectors like defence and aerospace. Balu Forge is fully committed to this vision and strategically leveraging these initiatives to drive capacity expansion.
With the government prioritizing self-reliance in defence manufacturing and aerospace engineering, we are investing in advanced precision manufacturing technologies and enhancing our capabilities to cater to these high-specification industries. Our focus is on developing cutting-edge solutions that meet stringent global standards, ensuring we play a pivotal role in India’s ambition to become a global manufacturing hub.
Additionally, infrastructure development under the ‘Viksit Bharat 2047’ initiative is set to strengthen logistics and supply chain efficiencies, further enabling us to scale operations and meet growing domestic and international demand. We are also exploring innovative materials and next-generation manufacturing techniques to stay ahead of industry trends, in sync with the government’s emphasis on boosting indigenous production and exports.
By capitalizing on these strategic initiatives and continuously evolving our technological capabilities, Balu Forge aims to cement its position as a key player in India’s precision engineering landscape, driving the nation’s manufacturing growth story forward.
With rapid advancements in Industry 4.0, AI, and automation, how do you see the future of precision engineering evolving?
The future of precision engineering is being reshaped by Industry 4.0, AI, and automation, driving unprecedented levels of efficiency, accuracy, and scalability. At Balu Forge, we see these advancements as catalysts for innovation—enhancing predictive maintenance, optimizing production processes, and ensuring zero-defect manufacturing. AI-driven design and real-time data analytics are revolutionizing how components are engineered, allowing for greater customization and reduced lead times. As the industry moves toward smart manufacturing, we are investing in next-gen technologies to stay ahead of the curve, reinforcing our commitment to quality, innovation, and global competitiveness.