§1What this business is
The outer shell is injection-moulded from ABS, sanded and painted; an EPS (thermocol) liner is glued inside, then the visor, pads and nylon straps are fitted by hand. Each helmet is tested before it gets the ISI mark. Buyers are helmet dealers, two-wheeler showrooms and accessory shops.
Capacity: Year 1 at 45% capacity (quantity not printed).
§2Is it right for you?
Who it is for
Someone with plastic-moulding experience and dealer links in the two-wheeler trade.
Who it is not for
Someone hoping to sell uncertified helmets — that is illegal.
Advantages
- Helmets are compulsory for two-wheeler riders — wide, steady demand
- Machinery under ₹14 L
- Small space and simple hand assembly
- Replacement demand every few years
Drawbacks
- BIS (ISI) certification is compulsory and needs a test lab
- Strong competition from big brands
- Moulds for new designs are costly
- Low price points in the mass market
Skills you need
- Injection moulding and painting
- Assembly and testing to IS 4151
- BIS paperwork
- Dealer and showroom sales
Why difficulty 3/5: Process is simple, but BIS certification and brand competition are real hurdles.
§3Market
Who buys
- Helmet and auto-accessory dealers
- Two-wheeler showrooms
- Fleet and delivery companies
How it sells
- Dealer network
- Showroom tie-ups
- Online marketplaces
Good to know
- The report notes the helmet must meet ISI standards before it carries the brand emblem.
- Year-1 sales are ₹75.79 L at 45% capacity.
§4Raw material & machinery
| Item | Qty | Cost |
|---|---|---|
| Injection moulding machine | 1 | ₹9,00,000 |
| Stitching machine (for pads) | 1 | ₹25,000 |
| Riveting machine | 1 | ₹70,000 |
| Paint dryer (oven) | 1 | ₹36,000 |
| Tensile / helmet testing machine | 1 | ₹2,65,000 |
| Dies and mechanical equipment | lot | ₹90,000 |
From: PMEGP sample project report — Helmet (prepared by Udyami/Samadhan)
- ABS granulesfor the outer shell
- EPS (expanded polystyrene)for the inner liner
- Polycarbonate resinfor visors
- Adhesive, foam, lock straps, stickers, bushesassembly parts
- Lacquer and water-based acrylic paint, cloth and meshfinishing and lining
From: PMEGP sample project report — Helmet (prepared by Udyami/Samadhan)
§5Licences & registration
- BIS licence for ISI mark — two-wheeler helmets come under a compulsory Quality Control Order (IS 4151)
- Udyam
- GST
- State pollution board consent and fire NOC (the report lists both)
- Trade licence
- Trademark
§6Schemes & subsidies
- PMEGPCentralActive15–35% subsidy
- MudraCentralActiveLoan up to ₹20 lakh, no collateral
- CGTMSECentralActiveNo collateral, up to ₹10 crore
- Stand-Up IndiaCentralClosed₹10 lakh – ₹1 crore loan
₹18.89 L project fits PMEGP, MUDRA (up to ₹20 L) and CGTMSE; Stand-Up India for SC/ST or women founders.
§7Money
How the investment is worked out: Report cost of project ₹18.89 L: plant & machinery ₹13.86 L, other assets ₹1.50 L, working capital ₹3.53 L; premises rented (₹15,000 a month assumed). Finance: own ₹1.89 L, term loan ₹13.82 L, working-capital loan ₹3.18 L.
Working capital: Working capital ₹3.53 L (bank ₹3.18 L).
Year not printed on the report — check current machinery prices.
§8Export potential
The report covers the home market only; it does not discuss export.
§9Risks — where people fail
- BIS licence delays or suspension
- Price war with big brands
- ABS and EPS price rise
- Product liability if a helmet fails
§1030 / 60 / 90-day plan
A general plan that applies to any business. A plan for this business will be added after research.
- Days 1–30: Visit a working two-wheeler helmet manufacturing unit, ask 10 buyers about price and quantity, and get quotations from 3 suppliers.
- Days 31–60: Udyam and the licences you need (BIS licence for ISI mark — two-wheeler helmets come under a compulsory Quality Control Order (IS 4151), Udyam), a project report (DPR), and the scheme or loan file.
- Days 61–90: Space and machines, trial production, and first deliveries to 10 customers.
§11Who to connect with
Associations, clusters and training institutes — the directory is being built. Connect
§12Watch
There is no episode on this business yet. Shows are coming soon on the Podcast page.
Want to start Two-Wheeler Helmet Manufacturing?
DPR, loan file or registration — ask us on WhatsApp.
¶Sources
Data review: 6 October 2026. Spotted a mistake? Report it. For information only — not legal or financial advice.