Bharat Forge Expands Aerospace Manufacturing with New Ring Mill

Bharat Forge’s Strategic Expansion into Aerospace Manufacturing

Bharat Forge Ltd., a global leader in advanced forging and precision engineering, has announced the establishment of a state-of-the-art ring mill dedicated to aerospace applications. The facility, expected to be operational by 2026, will produce high-performance components for aero-engine applications, marking a pivotal step in India’s ambitions to become a global aerospace manufacturing hub.

This development follows a strategic partnership with Pratt & Whitney Canada, a move that not only strengthens Bharat Forge’s international presence but also aligns with national initiatives like Make in India and Atmanirbhar Bharat. The ring mill will integrate cutting-edge technologies, adhering to stringent global standards for quality and traceability, positioning India as a credible player in the global aerospace supply chain.

As global aerospace markets seek diversified and resilient supply chains, Bharat Forge’s investment signals a shift in manufacturing capabilities from traditional centers to emerging economies. This article explores the strategic, technological, and economic implications of Bharat Forge’s aerospace expansion, grounded in verified data and industry insights.

Corporate Background and Evolution of Bharat Forge

Founded in 1961 by Nilkanthrao A. Kalyani in Pune, Maharashtra, Bharat Forge has grown into the flagship company of the Kalyani Group. Under the leadership of Baba Kalyani, the company has evolved from a domestic forging unit into a multinational engineering powerhouse with a presence in multiple sectors including automotive, defense, oil and gas, and now aerospace.

Key milestones in the company’s history include its expansion into global markets in the early 1990s and major investments in forging technology throughout the 2000s. These included the installation of high-capacity press lines and the establishment of advanced machining facilities, which laid the groundwork for its current capabilities in precision engineering.

Today, Bharat Forge operates 18 manufacturing facilities across five countries and boasts an annual forging capacity of over 770,000 tons. Its financial performance in FY 2022-23 includes consolidated revenues of ₹16,817 crores (approximately $2.03 billion), with an EBITDA margin of 21.7%, figures that underscore its robust operational health and capacity for strategic investments.

Strategic Importance of the Ring Mill

The announcement of the new ring mill on July 30, 2025, marks a significant diversification into aerospace manufacturing. The facility will be located in Baramati, Maharashtra, leveraging existing infrastructure and workforce expertise. It aims to support both domestic and international aerospace programs, focusing on aero-engine components that demand high precision and performance.

According to Amit Kalyani, Vice-Chairman and JMD of Bharat Forge, the partnership with Pratt & Whitney Canada “reinforces our commitment to the global aerospace ecosystem and advances India’s manufacturing capabilities in high-value aerospace components.” This strategic alignment with a major aerospace OEM provides Bharat Forge with access to global best practices and quality standards.

Frederic Lefebvre, Vice President of Supply Chain at Pratt & Whitney Canada, emphasized the importance of the partnerships in building a resilient global supply chain and enhancing India’s aerospace ecosystem. With over 800 employees in India, Pratt & Whitney has a longstanding presence in the country, further validating Bharat Forge’s role as a trusted partner.

“This underscores our commitment to building a resilient global supply chain and advancing India’s aerospace ecosystem.”, Frederic Lefebvre, Pratt & Whitney Canada

Ring Rolling Technology and Aerospace Applications

Ring rolling is a critical process in aerospace manufacturing, used to produce seamless, high-strength components such as turbine rings and structural elements. The technique involves the plastic deformation of heated metal rings, resulting in components with superior mechanical properties and dimensional accuracy.

Modern ring rolling systems employ CNC controls, temperature and pressure sensors, and automated feeding mechanisms. These capabilities ensure tight tolerances and repeatability, essential for aerospace applications where failure is not an option. The process also allows for material versatility, accommodating alloys like titanium and nickel-based superalloys commonly used in jet engines.

Seamless rolled rings offer several advantages over cast or welded alternatives. They maintain structural integrity under high temperatures, reduce material waste, and lower machining costs due to their near-net shape. These factors make them ideal for aerospace use, where performance, reliability, and cost-efficiency are paramount.

Global Aerospace Forging Market Dynamics

The global aerospace forging market is poised for significant growth. In 2024, its size was estimated at USD 26.3 billion, with projections reaching USD 36.0 billion by 2030. Other forecasts suggest even higher growth, with some estimates pointing to a USD 99.1 billion market by 2037. This expansion is fueled by rising demand for lightweight, durable components and advancements in materials and forging technologies.

The commercial-aircraft segment dominates the market, driven by increasing air travel and demand for fuel-efficient planes. Military aviation is also a key growth area, with a focus on high-performance forged components for next-generation aircraft. Materials like titanium and aluminum alloys are in high demand due to their strength-to-weight ratios.

India, with its growing engineering talent pool and supportive government policies, is well-positioned to capitalize on this trend. The country’s share in global aerospace manufacturing is expected to rise, especially as OEMs diversify supply chains in response to geopolitical and logistical challenges.

India’s Aerospace Vision and Policy Support

India’s aerospace ambitions are backed by national initiatives such as Make in India and Atmanirbhar Bharat. These programs aim to increase domestic manufacturing and reduce reliance on imports, particularly in strategic sectors like aerospace and defense. The Ministry of Defence has set a target of USD 26 billion in aerospace and defense output by 2025.

Prime Minister Narendra Modi has also identified Maintenance, Repair, and Overhaul (MRO) services as a sunrise sector, with plans to develop a USD 4 billion MRO hub by 2030. These initiatives create a conducive environment for companies like Bharat Forge to invest in high-value manufacturing capabilities.

Public-private partnerships are central to this strategy. Companies such as Tata Advanced Systems and Hindustan Aeronautics Ltd. have already partnered with global OEMs like Boeing and Airbus. Bharat Forge’s ring mill adds to this ecosystem, bolstering India’s credibility as a destination for aerospace manufacturing.

Conclusion

Bharat Forge’s establishment of a ring mill for aerospace applications is a strategic move that aligns with both corporate growth objectives and national policy goals. The facility will enhance India’s position in the global aerospace supply chain while providing Bharat Forge with access to high-margin, technology-intensive markets.

As the facility becomes operational in 2026, it will serve as a testament to India’s evolving manufacturing capabilities. The project exemplifies how strategic partnerships, technological investments, and policy alignment can drive industrial transformation. Bharat Forge’s initiative could pave the way for further advancements in India’s aerospace sector, fostering innovation, job creation, and economic growth.

FAQ

What is the purpose of Bharat Forge’s new ring mill?
The ring mill will manufacture high-performance aerospace components, particularly for aero-engine applications, using advanced ring rolling technology.

When will the ring mill be operational?
The facility is expected to be operational by 2026.

Who is Bharat Forge partnering with for this project?
Bharat Forge has signed a strategic partnership with Pratt & Whitney Canada for the supply of aerospace components.

How does this project support India’s aerospace ambitions?
The project aligns with national initiatives like Make in India and Atmanirbhar Bharat, contributing to India’s goal of becoming a global aerospace manufacturing hub.

Sources:
Bharat Forge Ltd.,
Pratt & Whitney Canada,
MarketsandMarkets,
Business Standard,
LiveMint,
IATA,
Make in India,
Ministry of Defence, India