Niir Project Consultancy Services (NPCS) through its network of project consultants in a wide range of business and technological disciplines is engaged in providing services to its clients by way of preparation of project reports. We provide the pre-investment information and business plans required for promoters, business leaders, young entrepreneurs, women entrepreneurs, investors, NRI (Non Resident India), startups, professionals looking to start their own venture. The comprehensive project profile reports cover all the aspects of business, from analyzing the market, confirming availability of various necessities such as plant & machinery, raw materials to forecasting the financial requirements. the scope of the report includes assessing market potential, negotiating with collaborators, investment decision making, corporate diversification planning etc. in a very planned manner by formulating detailed manufacturing techniques and forecasting financial aspects by estimating the cost of raw material, formulating the cash flow statement, projecting the balance sheet, break-even point, rate of return (ROR), etc. the DPR is formulated by highly accomplished and experienced consultants and the market research and analysis are supported by a panel of experts and digitized data bank.

How to Start Your Own Helmet Manufacturing Company Profitable Business Opportunities for Startups

Capacity 0 Plant and Machinery cost 0.00 Lakhs
Working Capital 0.00 Rate of Return (ROR) 0.00 %
Break Even Point (BEP) 0.00 % TCI 0.00 Lakhs
Cost of Project 0.00Lakhs



A helmet is a type of head protection that is worn on the head. A helmet, in particular, works in conjunction with the skull to shield the human brain. Ceremonial or symbolic helmets (such as a police officer's helmet in the United Kingdom) with no protective feature are sometimes worn. Soldiers wear Kevlar or other lightweight synthetic fabrics in their combat helmets. The word helmet comes from the Old English word helm, which refers to a protective head covering.

Helmets are worn by jockeys in horse racing, American football, ice hockey, cricket, baseball, camogie, hurling, and rock climbing, as well as in hazardous work environments such as manufacturing, mining, riot police, military aviation, and transportation (e.g. motorcycle helmets and bicycle helmets).

Since the 1990s, the majority of helmets have been made of resin or plastic, which may be lined with aramid fibres. Helmets have a much broader range of uses, including helmets tailored to the unique needs of a variety of sporting pursuits and work environments, and these helmets often use plastics and other synthetic materials for their light weight and shock absorbing properties.


Aramid fabrics, such as Kevlar and Twaron, are examples of synthetic fibres used to make helmets in the twenty-first century. In extreme crashes, race car helmets have a head and neck protection device that holds the helmet (and head) fixed to the body.



Related Project: Helmet Manufacturing Industry



Manufacturing Process of Helmet

The unassuming motorcycle helmet you take for granted every day is the product of a laborious manufacturing and assembly process that includes many steps and quality checks along the way to ensure that you get the best quality and protection while riding on the road.


Injection Molding the Child Parts:

A motorcycle helmet is made up of several different child components. The EPS shell is one of the most essential child pieces. The journey starts with tiny polystyrene beads that are expanded under pressure and heat to make ‘foam,' as it is called in the industry. In scientific terms, extended polystyrene is now polystyrene (EPS).

The non-expanded beads are fed into an injection moulding system, which produces an expanded polystyrene shell that serves as the motorcycle helmet's internal shell. However, this shell alone lacks the mechanical resistance to withstand high-impact forces, which is why it is protected by an ABS shell.

Using industrial adhesive, all cells are joined together to form a single external structure. The visor in helmets is made in a similar way, using transparent polyurethane beans that are pressed together under high pressure and temperature to produce clear, mirrored, or rainbow-hued visors by adding various additives.



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Buffing & Sanding

The outer shell is then taken to the buffing and sanding station, where the entire structure is polished and the joining marks are removed. A special polishing machine and emery paper are used to smooth the surface left behind by the injection moulding machine.  This not only removes any excess materials from the helmet's surface, but it also prepares the shell for the next steps in the painting process. It should be remembered that not all helmets are painted, and if this is the case, the helmet will continue to the assembly line today to have the visors and straps fitted before being packaged and shipped.


Painting & Decals

Following the buffing process, the helmet is thoroughly washed to remove any small particles or dust that could influence the overall outcome of the painting process. Many precautions are taken to ensure that no dust remains on the surface of the helmet, including rubbing the surface with industrial alcohol and subjecting it to vacuum machines where even the tiniest dust particle is fully removed until the helmet is sent to a hermetically sealed painting booth.

The surface is painted with a base coat and then another layer of the primary colour, depending on the pre-decided colour and design choices. The colours and mixes are done by a professional, and the surface is painted with a painting gun. After this process is completed, the helmet is sent to the Assembly line's decal area, where expert workers apply decorative and colourful decals to the helmet and allow it to set for 3 to 4 hours (maximum of 8 hours) before returning to the paint shop for a final layer of top coat.



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Attaching the visors and straps

Staff design the straps and strapping mechanism, as well as other rivets and bushes that go into the helmet to secure the strap in place, in a different section of the manufacturing unit. Staff on the production line combine the painted shell with the visor mechanism and the strapping mechanism using various specialised tools for punching holes and attaching the straps protection until the helmet leaves the paint shop. Die-cut and laser machines are used to precisely cut the pads and inner lining of the helmet with a precision of a few millimeters, ensuring the best comfort and protection for the user.


Multiple quality checks

Before being moved on to the next section of the Assembly Line on the manufacturing phase, each of the above phases undergoes a rigorous quality check at the end of the process to ensure that the child parts follow regulatory standards and internal quality parameters. To minimise waste, any component that does not meet the requisite quality parameters is discarded and recycled. The element becomes eligible to carry the ISI mark as well as the company's insignia until it is sent forward to be packed and shipped until the quality expert is fully satisfied that the helmet meets all requisite specifications and safety standards.


Packaging & Shipping

Finally, the completed product is packed and delivered to various locations around the world, along with documentation to assist the consumer in making the most of the product.



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Market Outlook


In 2018, the global smart helmet market was worth USD 372.4 million, and it is projected to develop at a CAGR of 18.6% from 2019 to 2025. Smart helmets are equipped with a variety of electronic devices and sensors that enable users to collect real-time data and, in the long run, reduce operational risks and improve safety. Helmets are becoming increasingly common among bicyclists and motorcyclists due to their increased protection, safety, and comfort. They're also seen in a variety of sporting activities, as well as military and firefighting operations.

Government-imposed road safety regulations, the growing adoption of advanced wearable technology, and increased knowledge of personal safety are expected to drive demand. Asia Pacific is projected to be the fastest-growing regional market for smart helmets. The two-wheeler sales, rapid urbanisation in developing economies such as India and China, and the region's increasing manufacturing sector are expected to be the region's main growth drivers.



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Market in India

Due to increasingly stringent regulations for both commuters and helmet manufacturers in India, the two-wheeler helmet market is expected to expand at a double-digit pace. The selling of two-wheeler helmets is expected to continue growing across the country in the coming years, thanks to increased consumer spending on luxury goods and increased safety awareness. The government's new rules prohibiting the use of non-ISI helmets would only increase revenue for organized helmet manufacturers.

Covid-19 has wreaked havoc on the Indian economy, but it has also provided an impetus for innovation. Our manufacturing plants were only closed for a few days before we began producing face shields, goggles, and masks.

People will definitely return to their personal mode of transportation rather than using public transportation as social distancing becomes the new standard. Since two-wheelers are the most convenient mode of transportation in India, sales will increase, and there will be a large demand for used two-wheelers as well. This will undoubtedly increase demand for helmets.

In addition, with the implementation of some stringent government policies, consumer demand is expected to rise. The market potential is significant, and the government's new policy prohibiting non-ISI approved helmets would provide a significant boost to organized players in the helmet industry by increasing demand. Both of these factors would only increase the helmet industry's revenue.






According to government estimates, road accidents cost 3% of GDP, and the amount of people killed in them is comparable to the current pandemic. As a result, the government is concentrating on improving rider safety by constantly updating themselves and implementing new regulations. For example, according to the Motor Vehicle Bill, all two-wheeler riders must now wear a helmet.

Second, the government has enacted legislation prohibiting the manufacture, selling, and use of non-ISI approved helmets. This policy will take effect on March 1, 2021, and it will be a significant step in improving the safety of two-wheeler riders. Third, the government has acknowledged that limiting the weight of helmets limits the rider's protection, so the clause has been removed, which would allow organized players to produce quality helmets. All of these measures are intended to improve rider safety.


List of Best Helmet Brands in India for Bike Riders:


The best helmet brands in India are mentioned below. Some are regional, whereas others are global. They have a good online and offline presence for the most part. Go through the list below and connect with a brand that interests you the most. Please keep in mind that the following list of the best helmet brands in India is not in any particular order.


·         Vega: What started in India in 1982 has now spread across continents in 2020. Vega is a well-known brand that is also one of the most popular. The company has a wide variety of helmets and accessories, with an emphasis on both design and quality.


·         Steelbird: Steelbird Hi-tech India Ltd. is an excellent example of how a small family company grew into a well-known brand. Steelbird is a brand that caters to a wide range of consumer segments, with helmets ranging from open-face to Motocross. Customized helmets are also available.


·         Studds: Among Indian bikers, Studds is a well-known brand. In 1973, the company started operations. It is also known as the largest helmet maker in the world. Studds places a strong emphasis on consistency and creativity. It sells fashionable helmets as well as useful accessories.


·         LS2: LS2 is a globally recognised brand that has evolved as a result of its R&D efforts. Three pillars of the brand's success are in-house experience, precision assembly, and quality control. They have a large selection of designer helmets.



Market Research: - Market Research Report


·         THH: THH stands for Tong-ho-Hsing and is based in Taiwan. Their helmets are known for being lightweight, ventilated, and constructed from high-quality materials. THH creates exciting models and graphics on a daily basis. In India, the company hopes to manufacture 10,000 helmets a day.



·         Wrangler: Wrangler is a well-known American brand. It is well-known for its apparel and accessories. Helmets from Wrangler are also common. In India, they sell open-face, full-face, half-face, and other types of helmets. They're fashionable yet remaining cost-effective.


·         Royal Enfield: Many who ride Royal Enfield motorcycles tend to wear a Royal Enfield helmet. Their helmets come in a variety of sizes and colours to complement various bike styles. They're stylish, easy, and long-lasting.


·         Aerostar: Aerostar helmets are reasonably priced. The company has a significant presence in the Indian market. It has a wide selection of high-quality helmets.


·         HJC: For over forty years, HJC Helmets has been serving motorcycle enthusiasts. Helmets for bicycles, motorcycles, and auto (car racing) are all available from the company. Their focus is on high-quality, fashionable designs.


·         SHOEI: SHOEI is recognised as the world's premium helmet manufacturer. Their goods are the result of extensive research and development. For bike riders, the company offers both on-road and off-road helmets.


·         Gliders: Gliders is a subsidiary of TP Industries and is based in India. Since 1993, the business has catered to the needs of bikers. Their helmets are recognised for their high quality and safety. In 2005, they launched NXT, a line of sporty helmets.



Related Video: Helmet manufacturing business



·         Fastrack: Fastrack is a popular youth brand known for its watches. They later expanded into accessories such as eyewear and handbags. Bike helmets are another product line they've looked at. Fastrack helmets, like their other products, have an attractive style.


·         Autofy: This Company specialises in car accessories and riding clothing. They have a range of ‘interesting' items. Their helmets are uncomplicated but appealing. These helmets are available on their website for a reasonable price. They also offer promotional discounts.


·         AGV: Since 1947, the AGV brand has been at the forefront of providing helmets. It is a well-known brand that provides items tailored to a biker's riding style. They have appealing helmets in the racing, sport, touring, off-road, and urban categories.


·         Aaron: The headquarters of Aaron Helmets Pvt. Ltd. are in New Delhi. Aaron has risen to the top of India's helmet industry thanks to its innovation, efficiency, and science. They have everything from Bluetooth helmets to Moto-X helmets. Their collection is chock-full of eye-catching colours and patterns.


·         Manufacturas Tomas: MT is the abbreviation for Manufacturas Tomas. The company that makes these helmets is based in Spain. In Europe, MT helmets have a decent reputation. More than a hundred countries on five continents are represented by the brand. It provides a wide range of choices for bikers.


·         SMK: SMK is a manufacturer of technologically advanced helmets. They're not only clean, but they're also attractive. The SMK helmets are conceptualised and designed entirely in Europe. When it comes to SMK, style and protection go hand in hand.



·         Bell Helmets: One look at their catalogue will persuade you that their brand is exclusive. Their helmets are unlike any other on the market in terms of style. They have a wide variety of helmets to choose from, from classic to edgy.


·         ARAI: ARAI Helmets was founded in 1937. They've provided service to the market based on their security, efficiency, and comfort values. These helmets are made by hand by trained artisans. You will learn more about how they handcraft the helmets by visiting their website.



·         Shark: Shark is a French fashion label. Health, efficiency, and engineering are all priorities for them. If you're looking for high-end helmets, Shark helmets may be the answer.



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NIIR PROJECT CONSULTANCY SERVICES (NPCS) is a reliable name in the industrial world for offering integrated technical consultancy services. NPCS is manned by engineers, planners, specialists, financial experts, economic analysts and design specialists with extensive experience in the related industries.

Our various services are: Detailed Project Report,  Business Plan for Manufacturing Plant, Start-up Ideas, Business Ideas for Entrepreneurs, Start up Business Opportunities, entrepreneurship projects, Successful Business Plan, Industry Trends, Market Research, Manufacturing Process, Machinery, Raw Materials, project report, Cost and Revenue, Pre-feasibility study for Profitable Manufacturing Business, Project Identification, Project Feasibility and Market Study, Identification of Profitable Industrial Project Opportunities, Business Opportunities, Investment Opportunities for Most Profitable Business in India, Manufacturing Business Ideas, Preparation of Project Profile, Pre-Investment and Pre-Feasibility Study, Market Research Study, Preparation of Techno-Economic Feasibility Report, Identification and Section of Plant, Process, Equipment, General Guidance, Startup Help, Technical and Commercial Counseling for setting up new industrial project and Most Profitable Small Scale Business.

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And before diversifying/venturing into any product, wish to study the following aspects of the identified product:

• Good Present/Future Demand
• Export-Import Market Potential
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The report first focuses on enhancing the basic knowledge of the entrepreneur about the main product, by elucidating details like product definition, its uses and applications, industry segmentation as well as an overall overview of the industry sector in India. The report then helps an entrepreneur identify the target customer group of its product. It further helps in making sound investment decision by listing and then elaborating on factors that will contribute to the growth of product consumption in India and also talks about the foreign trade of the product along with the list of top importing and top exporting countries. Report includes graphical representation and forecasts of key data discussed in the above mentioned segment. It further explicates the growth potential of the product.

The report includes other market data like key players in the Industry segment along with their contact information and recent developments. It includes crucial information like raw material requirements, list of machinery and manufacturing process for the plant. Core project financials like plant capacity, costs involved in setting up of project, working capital requirements, projected revenue and profit are further listed in the report.

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Our Market Survey cum Detailed Techno Economic Feasibility Report Contains following information:



Ø  Introduction

·         Project Introduction

·         Project Objective and Strategy

·         Concise History of the Product

·         Properties

·         BIS (Bureau of Indian Standards) Provision & Specification

·         Uses & Applications


Ø  Market Study and Assessment

·         Current Indian Market Scenario

·         Present Market Demand and Supply

·         Estimated Future Market Demand and Forecast

·         Statistics of Import & Export

·         Names & Addresses of Existing Units (Present Players)

·         Market Opportunity


Ø  Raw Material

·         List of Raw Materials

·         Properties of Raw Materials

·         Prescribed Quality of Raw Materials

·         List of Suppliers and Manufacturers


Ø  Personnel (Manpower) Requirements

·         Requirement of Staff & Labor (Skilled and Unskilled) Managerial, Technical, Office Staff and Marketing Personnel


Ø  Plant and Machinery

·         List of Plant & Machinery

·         Miscellaneous Items

·         Appliances & Equipments

·         Laboratory Equipments & Accessories

·         Electrification

·         Electric Load & Water

·         Maintenance Cost

·         Sources of Plant & Machinery (Suppliers and Manufacturers)


Ø  Manufacturing Process and Formulations

·         Detailed Process of Manufacture with Formulation

·         Packaging Required

·         Process Flow Sheet Diagram


Ø  Infrastructure and Utilities

·         Project Location

·         Requirement of Land Area

·         Rates of the Land

·         Built Up Area

·         Construction Schedule

·         Plant Layout and Requirement of Utilities


Project at a Glance

Along with financial details as under:


  •     Assumptions for Profitability workings

  •    Plant Economics

  •    Production Schedule

  •    Land & Building

            Factory Land & Building

            Site Development Expenses

  •    Plant & Machinery

             Indigenous Machineries

            Other Machineries (Miscellaneous, Laboratory etc.)

  •    Other Fixed Assets

            Furniture & Fixtures

            Pre-operative and Preliminary Expenses

            Technical Knowhow

            Provision of Contingencies

  •   Working Capital Requirement Per Month

             Raw Material

            Packing Material

            Lab & ETP Chemical Cost

           Consumable Store

  •   Overheads Required Per Month And Per Annum

         Utilities & Overheads (Power, Water and Fuel Expenses etc.)

             Royalty and Other Charges

            Selling and Distribution Expenses

  •    Salary and Wages

  •    Turnover Per Annum

  •   Share Capital

            Equity Capital

            Preference Share Capital


  •    Annexure 1:: Cost of Project and Means of Finance

  •    Annexure 2::  Profitability and Net Cash Accruals


                Expenses/Cost of Products/Services/Items

                Gross Profit

                Financial Charges     

                Total Cost of Sales

                Net Profit After Taxes

                Net Cash Accruals

  •   Annexure 3 :: Assessment of Working Capital requirements

                Current Assets

                Gross Working. Capital

                Current Liabilities

                Net Working Capital

                Working Note for Calculation of Work-in-process

  •    Annexure 4 :: Sources and Disposition of Funds

  •    Annexure 5 :: Projected Balance Sheets

                ROI (Average of Fixed Assets)

                RONW (Average of Share Capital)

                ROI (Average of Total Assets)

  •    Annexure 6 :: Profitability ratios


                Earnings Per Share (EPS)


             Debt Equity Ratio

        Annexure 7   :: Break-Even Analysis

                Variable Cost & Expenses

                Semi-Var./Semi-Fixed Exp.

                Profit Volume Ratio (PVR)

                Fixed Expenses / Cost 


  •   Annexure 8 to 11:: Sensitivity Analysis-Price/Volume

            Resultant N.P.B.T

            Resultant D.S.C.R

   Resultant PV Ratio

   Resultant DER

  Resultant ROI

          Resultant BEP

  •    Annexure 12 :: Shareholding Pattern and Stake Status

        Equity Capital

        Preference Share Capital

  •   Annexure 13 :: Quantitative Details-Output/Sales/Stocks

        Determined Capacity P.A of Products/Services

        Achievable Efficiency/Yield % of Products/Services/Items 

        Net Usable Load/Capacity of Products/Services/Items   

       Expected Sales/ Revenue/ Income of Products/ Services/ Items   

  •    Annexure 14 :: Product wise domestic Sales Realisation

  •    Annexure 15 :: Total Raw Material Cost

  •    Annexure 16 :: Raw Material Cost per unit

  •    Annexure 17 :: Total Lab & ETP Chemical Cost

  •    Annexure 18  :: Consumables, Store etc.,

  •    Annexure 19  :: Packing Material Cost

  •    Annexure 20  :: Packing Material Cost Per Unit

  •    Annexure 21 :: Employees Expenses

  •    Annexure 22 :: Fuel Expenses

  •    Annexure 23 :: Power/Electricity Expenses

  •    Annexure 24 :: Royalty & Other Charges

  •    Annexure 25 :: Repairs & Maintenance Exp.

  •    Annexure 26 :: Other Mfg. Expenses

  •    Annexure 27 :: Administration Expenses

  •    Annexure 28 :: Selling Expenses

  •    Annexure 29 :: Depreciation Charges – as per Books (Total)

  •   Annexure 30   :: Depreciation Charges – as per Books (P & M)

  •   Annexure 31   :: Depreciation Charges - As per IT Act WDV (Total)

  •   Annexure 32   :: Depreciation Charges - As per IT Act WDV (P & M)

  •   Annexure 33   :: Interest and Repayment - Term Loans

  •   Annexure 34   :: Tax on Profits

  •   Annexure 35   ::Projected Pay-Back Period And IRR