8 High Growth Manufacturing Business Opportunities for Startups

Startups are rapidly moving towards industries with high growth and sustainability. Entrepreneurs can take advantage of innovative products and booming markets, from advanced materials to renewable fuel alternatives. This article examines eight promising products, from bio coal to EV Batteries, each with information on their manufacturing business, application, and growth in the market.

We highlight the key steps as well as raw materials, plant requirements and market demand to help you assess feasibility.

Mustard Straw Briquettes for Bio Coal

Compressed agricultural waste can be used to make bio-coal briquettes. After harvesting, mustard farmers produce large quantities of stalks that can be compressed into solid fuel briquettes. The final briquettes will be further dried until they reach the ideal moisture content (10%), before packaging. The steps are summarized below:

• Material preparation: Cleanse and dry the straw.
• Grating: Grind the straw into small pieces.
  
• Briquetting: Press the ground straw under high pressure to solid blocks.
  
• After processing, Cool and dry the briquettes in order to maintain moisture content.
  

Benefits: Mustard straw briquettes have a low ash content (10%) and are carbon neutral. Moreover, the briquettes offer a calorific value of 4200 kcal/kg, which is comparable to low-grade coke. In addition, they contain a low amount of ash (10%), which makes them a cleaner fuel alternative. Therefore, they are an excellent solid fuel option to use in industrial boilers, power stations, and household stoves.

Demand & Growth: The global biomass market (including agricultural residues and wood waste) is growing due to tighter emission standards and renewable energy goals. The coal briquette market, for example, was estimated at a few hundred million USD with an annual growth of 4%. Demand for industrial boilers and rural energy is increasing in India and other mustard-growing regions. Table:

Table 1 shows that mustard straw is a good source of energy compared to other biomass fuels. Bio-coal briquettes are a growing and stable market as governments and industries strive to create sustainable energy.

Related:  How to Start a Bio Coal Briquettes Manufacturing Business

Fuel Briquettes made from Cashew Nut Deoiled Cake

Fuel briquettes are made from de-oiled cashew cake (CNSL). These fuel briquettes utilize the by-products produced during cashew processing. The de-oiled cake is rich in organic material after the cashew shell liquid has been extracted. This residue can then be turned into fuel briquettes. The steps of production are the same as for other biomass briquettes.

• Source raw material from cashew processing plants. India, Vietnam and Nigeria are the major producers.
  
• Drying and milling – Spread the cake out to dry. Grinding into small pieces.
  
• Mixing: DOC is often mixed with a natural binder, such as starch or molasses, or another biomass, like sawdust or coconut coir, to improve the binding.
  
• Briquetting: Press the mixture under high pressure in a briquette maker.
  
• Storage/Cooling: Let briquettes cool, then place them in bags or pallets.
  

Benefits and challenges: Cashew nut DOC briquettes are very calorific (4500-5000 kcal/kg – higher than most woods), due to the residual oils and phenolic compounds. They burn hotter and longer. They are therefore ideal for boilers, brick kilns and tile factories that require high heat. DOC briquettes solve a problem for cashew processing companies as well. Raw cashew cakes contain resins and acids which can cause toxic fumes when burned.

Market and Demand: The fuel-briquette market is a niche, but it’s growing as cashews are processed. These briquettes are suitable for brick kilns, cement plants and other low-cost energy sources. Entrepreneurs can target areas with large cashew-producing industries (e.g. India’s Kerala/Karnataka coasts). The government’s incentives to use biomass fuels and environmental regulations that limit coal usage are key drivers.

Gluconic Acid from Potato

Gluconic acid, a versatile organic acid, is widely used in agriculture (in metal-chelates and plant nutrients). Moreover, it serves as a mineral supplement (as an acidifier), and in addition, it plays an important role in food preservation (as preservatives and acidity regulators). Furthermore, its production primarily involves fermentation and subsequent purification. Consequently, the typical process is:

• Potato preparation: Clean and select potatoes with high starch content. Chop or grind tubers to expose the starch.
  
• Enzymatic Hydrolysis: Add amylase enzymes and mix potato mash in water to convert starch into glucose syrup. This produces a solution rich in sugar (glucose as the feedstock).
  
• Fermentation: In large fermenters, inoculate the glucose solution with microorganisms like Gluconobacter and Aspergillus niger. These microbes can convert glucose to gluconic acids under controlled conditions (30-35degC, neutral pH). This process may take a few days.
  
• Purification: After fermentation, filter the biomass and then treat broth. Precipitate by adding calcium hydroxide to form calcium-gluconate (Ca(OH2)2), filter, and then react with an acid (sulfuric, hydrochloric, or hydrochloric), to regenerate free-gluconic acid, and precipitate gypsum.
  
• Concentration and drying: Concentrate the acid purified by evaporation, and spray-dry it if you want to crystallize or powderize.
  

Benefits: The production of potatoes is both sustainable (potatoes grow in abundance and are available in most regions) and competitively priced if the local potato waste is used (such as peels and culls).

Gluconic Acid has a wide market: It is used in drinks and sauces as an acidulant. Moreover, it acts as a chelator that helps minerals absorb efficiently, and in addition, it is applied in building cleaning since it binds the minerals in hard water. Furthermore, the rising demand for biodegradable and natural chemicals is significantly increasing their popularity.

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Lithium-Ion Batteries for Electric Vehicles

Electric vehicle (EV), or battery, is a sector that has seen rapid growth due to the global adoption of zero-emission vehicles. Lithium-ion battery technology dominates the EV market. The two main chemistries are LFP (Lithium Iron Phosphate), and NMC(Nickel Manganese Cobalt). Entrepreneurs who are interested in this field should understand the manufacturing process of batteries and the market trends.

Battery Types: LFP and NMC

• LFP (LiFePO4) Batteries use iron and phosphate as the cathode. These batteries are non-toxic and safe (low risk of fire), have a long cycle life (2000+ cycles), and are less expensive. They have a lower power density (90 to 160 Wh/kg), and a typically lower voltage. LFP is widely used in China by electric buses and economy vehicles.
  
• Nickel, manganese, and cobalt are all present in NMC batteries (LiNiMnCoO2). These batteries are suitable for long-range EVs, as they have a higher energy density (180-220Wh/kg) with a higher voltage (used by Tesla and GM). Cost (cobalt mining is ethically questionable and expensive) and thermal stability are the drawbacks.
  

Manufacturing Process

The manufacturing process for lithium-ion batteries is complicated and capital-intensive. The key steps include:

1. Preparation of raw materials: Purchase high-purity compounds such as lithium, nickel, cobalt or manganese anode powders, graphite, and silicon anode, along with binders, solvents, and other additives.
   
2. Electrode formulation: Form a slurry by mixing cathode-active materials (NMC powders or LFP) with solvents and binders. Anode: Separately combine graphite with a binder.
   
3. Coating and drying: Apply the anode and cathode solutions to aluminum foil and copper foil, respectively. To remove the solvents, dry the foils coated with the cathode slurry in an oven.
   
4. Calendering (calendering) and slitting the electrodes: Press them to a precise thickness, then cut them into strips.
   
5. Cell assembly: In an air-tight room, stack the cathode or anode with a separator between them to create cells or jellyrolls. Insert into metal cans and pouch cases.
   
6. Filling and sealing cells with electrolyte liquid (lithium in organic solvent).
   
7. Test and sort the cells by quality and capacity. This process can take several days.
   
8. Module/pack assembly: Connect cells to modules with aluminum housing and add battery management electronic components. Assemble into packs for EV installations.
   

Investors should invest in specialized equipment (coating machines, winding machines and formation cyclers as well as clean rooms).

Market trends

The EV Revolution is driving battery demand by double-digits. The global lithium-ion market, for example, was $60-80 billion in the middle of 2020 and is expected to reach $180 billion by 2030 (roughly a 20% CAGR). The annual battery production capacity will increase from 500 GWh in 2020 to 1000 GWh in 2030.

• LFP segment: LFP is expected to grow the fastest in segments that are cost-sensitive (cheaper cars and stationary storage, as well as budget EVs).
  
• The NMC segment continues to be the most popular choice for high-performance EVs despite raw material supply issues.
  

Entrepreneurs can focus on a specific niche, such as assembling batteries for stationary storage or e-mobility, or specialising in battery components. Battery recycling is a new business.

Related: Starting a Lithium-Ion Battery Assembly Business: Key Considerations and Challenges

Copper Ingots & Rolling

Copper is an essential industrial metal. It’s used in electrical wiring, electronics and plumbing. The process of converting refined copper into useful shapes is required to set up a copper melting, casting, and rolling plant. The basic steps include:

• Source raw materials: Copper cathodes or high-grade scrap can be used as feedstock.
  
• Melting and casting: Melt copper in an induction or reverberatory furnace. Cast the molten copper into ingots and billets with a continuous caster or ingot moulds.
  
• Hot rolling: The ingots/billets are heated and then rolled through mills, reducing the thickness to produce copper sheets, strips or bars.
  
• Cold rolling: Further rolling at room temperatures can improve surface finish, mechanical properties, and thickness for thin foils and specialized products.
  
• Finishing: Heat-treat (anneal) the material to soften it, then cut into size and plate with tin if desired (e.g. PCBs). Cleaning and inspecting for quality.
  

The temperature and speed of the rolling mills must be precisely controlled. A plant will also need furnaces, crushing equipment (if it is recycling scrap), molds for casting, and finishing tools. Energy costs are high because of the power consumption (furnaces and mills).

Market demand: Demand for copper is influenced by construction and electrification. Power cables, renewable energies (wind turbines, sun) and electric vehicles are expected to drive the global copper usage growth of 5-7% per year. The global copper market, in context, is estimated to be worth hundreds of billions of dollars, and will reach $340billion by 2030.

Startups will find many opportunities in the copper recycling and rolling industry, particularly in countries that have a growing economy or are undertaking infrastructure projects. Customers include sheet metal fabricators and electronic component manufacturers, as well as wire-drawing (copper rod) companies.

Coconut Milk

Coconut milk is made from the liquid extracted from grated coconut flesh. It is a traditional ingredient used in tropical cuisines. It has a rich taste and is becoming more popular as a dairy substitute due to its health benefits. Coconut milk is produced in a typical industrial way:

• Raw Material: Fresh mature coconuts (copra) or coconut meat (fresh/dried). The Philippines, Indonesia, India, and Sri Lanka are the main producers.
  
• Extraction: Grate or shred white kernels from fresh coconuts. Mix with warm water, and either use a mechanical press or a hydraulic press to knead it by hand. Rehydrate copra powder in the same way for coconut milk powder. This first pressing yields thick coconut milk from the “first press” (high in fat). Second, lighter pressings with more water produce a second-quality diluted milk.
  
• Filtration: The liquid is passed through centrifuges or filters to remove particulates and fibers. Some plants homogenize milk to improve shelf life and consistency.
  
• Preservation: Coconut Milk spoils rapidly due to enzyme activity. Commercial plants pasteurize coconut milk (heat it to kill microbes), and/or add preservatives (as permitted by food regulations).
  
• Packaging: Depending on the market, pack the milk in Tetra Pak cartons or bottles. Coconut milk powder is also becoming more popular. It is produced by spray-drying or drum-drying, the filtered milk. The powdered version has a longer shelf-life and is easier to transport.
  
• By-products: The remaining fiber (“pulp”) may be dried to make coir, or animal feed. Separating coconut oil before or during the processing can be done to increase revenue.
  

Market Demand

Global coconut milk demand is growing. Many forecasts predict that it will double or triple in the next decade. One report, for example, projected that the market would reach $2-3 billion in 2030, with an 8-10% CAGR. This was driven by health and well-being trends and vegan diets.

Important considerations for plants include food-grade hygiene (to avoid contamination), temperature control (to stop enzyme browning), as well as a stable supply of high-quality coconuts of high quality. Karnataka, a state in India, has developed integrated units that produce coconut milk and virgin oil from the same coconuts.

Aluminium Hydroxide from Aluminium Oxide

Aluminium hydroxide is used as a filler for plastics, rubber, and pharmaceuticals. It can also be used to treat water and as an antacid. The most common way to produce it is by chemically converting aluminum oxide (Alumina, Al2O3) into a hydroxide. The standard industrial route involves the Bayer intermediate (sodium-aluminate) or treating alumina directly.

• Alkali dissolution: Dissolve the alumina under pressure in a concentrated hot sodium hydroxide solution. This will form sodium aluminate. Alternatively, dissolve alumina at high temperatures in caustic soap to obtain a clear aluminate liquid.
  
• Precipitation: Add aluminium hydroxide to the cooled aluminate or adjust pH (by adding acids or cooling) in order to precipitate AlOH3. It is important to do this gradually in order to obtain fine and uniform crystals.
  
• Filtration and washing: Remove the precipitated sodium trihydrate by filtering it out and then wash to remove any residual salts.
  
• Calcination: If needed for special uses, a part of the AlOH3 can be calcined to produce activated alumina (or more refined forms) by heating it strongly. The final product is usually made by drying the Al(OH).
  

Aluminium trihydroxide is the result, a powdery white substance. It is non-toxic and relatively inert. It is a good flame retardant because it releases water (up to 200 °C) when heated. This cools down the material, forming a protective layer of alumina.

Global Aluminium Hydroxide Market Demand

The global market for aluminium hydroxide is large and growing. It was estimated to be around $12 billion in 2024 and is expected to grow by 4-5% per year until 2030. The growth drivers are stricter fire safety regulations (leading more FR additives to be used in textiles, cables and plastics) as well as the increasing use of flame-retardant coatings, paints and building materials.

Entrepreneurs can tap into this market by setting up shop near sources of alumina, such as bauxite/alumina factories. They should also focus on the high-volume flame-retardant grade. Sustainability and by-products are important: The process produces sodium sulfate, which must be controlled (if you use sulfuric acid wash).

Silica Gel made from Sodium Silicate & Sulfuric Acid

Silica gel, a porous form of silicon dioxide, is widely used as a desiccant and as an adsorbent. The most common way to make it is by reacting a solution of sodium silicate (water glass), with sulfuric acid. The basic steps include:

Preparation

• To prepare sodium silicate, either buy sodium silicate commercially or dissolve silica sand in a strong soda solution (sodium chloride) at high temperatures to form Na2SiO3 solutions. Recipes can adjust the ratio of SiO2 to Na2O.
  
• Add sulfuric acid (H2SO4) slowly to the sodium silicate solution. The reaction is: Na2SiO3+H2SO4 = 2NaHSO4+SiO2*H2O(silica hydrate). A gelatinous silica precipitate forms. To control the gel particle size, this step requires cooling with a pH controlled (usually around 7).
  
• The gel can be aged by keeping the silica gel wet slurry at a slightly higher temperature for several hours. This will strengthen the gel’s network (aging, or syneresis).
  
• Washing: Filter the silica wet and wash it multiple times in water to remove the sodium sulfate product.
  
• Drying and activation. Dry the gel after washing (e.g. in hot air ovens). Then heat it (200-300 °C) to remove any residual moisture. This will yield porous amorphous silicon.
  
• Processing into beads/powder: Depending on the application, dried silica may be crushed to irregular grains or formed as beads (dropping wet gelatine in oil or sulfuric acids to form spherical beads). The product is then cooled and sieved into size.
  

Applications

Silica Gel adsorbs water – used to dry electronics, leather goods, pharmaceuticals, and other products. Also, it is used for chromatography and drying air streams. It can also be used as a support for catalysts. Analysts report a 6-10% CAGR for the global desiccant industry. This is due to ecommerce packaging and increased pharma standards.

Market Demand

Analysts expect the silica market to be in the low tens of billions of dollars (USD) range by 2030. The growth is stable, driven by the increasing consumption of moisture-sensitive products (like mobile electronic devices) and environmental concerns. Packaging companies and industrial users are the main consumers (pipelines, dryer systems).

The silica gel factory requires chemical reactors and dryers. It may also require bead formation towers. The waste management is easy (the sodium-sulfate washing water can be reused, or evaporated for salt recovery). Production is low-tech. The main challenge is to control purity and particle sizes.

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How NPCS Can Help You Build Your Business

Niir Project Consultancy Services (NPCS) prepares detailed market survey-cum-techno economic feasibility reports for all these industries. NPCS reports cover Manufacturing Business, raw materials, plant layout, and financial projections. This helps entrepreneurs evaluate the feasibility of setting up new manufacturing ventures. By leveraging NPCS’s expertise, startups can make informed decisions on capital investment and market entry strategies.

For more information, check out our related video

FAQ

Q: What are bio coal briquettes from mustard straw, and why start this business?

A: Bio coal briquettes are compressed fuel blocks made from mustard straw (agro-waste). They burn cleanly and have a high energy content, making them a renewable substitute for coal. Starting this business is attractive because raw material is cheap waste, demand is rising for green fuels, and technology (briquetting machines) is well-established.

Q: How do you make fuel briquettes from cashew nut de-oiled cake?

A: Cashew nut de-oiled cake (DOC) is the fibrous residue left after extracting cashew nut shell liquid. To make briquettes, the DOC is dried, ground, and mixed with a binder (like cassava starch) or other biomass to improve binding. It’s then fed into a briquette press under high pressure.

Q: What is gluconic acid used for, and why use a potato?

A: Gluconic acid is used as a mild acidulant in foods (e.g., soft drinks, jams), as a chelating agent in pharmaceuticals (to help absorb minerals), and in agriculture (fertilizers and soil conditioners). It is valued for being non-toxic and biodegradable. Producing gluconic acid from potato is effective because potato starch can be easily converted to glucose, a fermentable sugar.

Q: What are the differences between LFP and NMC EV batteries?

 A: Lithium Iron Phosphate (LFP) batteries use iron-phosphate cathodes. They are cheaper, safer (less prone to overheating), and have very long life (many charge cycles), but lower energy density. LFP is common in budget EVs and energy storage systems. Nickel-Manganese-Cobalt (NMC) batteries have a nickel-rich cathode.

Q: What industries use copper ingots and rolled products?

A: Copper ingots and rolled products (sheets, strips, bars and rods) are widely used wherever conductivity and corrosion resistance are needed. Key industries include electrical (wires, cables, busbars), electronics (printed circuit boards, connectors), construction (plumbing, roofing, architectural), automotive (radiators, wiring), and industrial machinery. Rolled copper sheets are used in cookware and heat exchangers. 

Q: How is coconut milk produced on an industrial scale?

A: Industrial coconut milk Manufacturing Business involves extracting liquid from grated coconut. Coconuts are dehusked and grated, then either mechanically pressed or mixed with warm water and squeezed to separate the white milk from the fiber. Byproducts like coconut oil and fiber are often recovered. Consistency is achieved by homogenizing the milk. Proper sanitation and quality control are critical, as coconut milk can spoil quickly.

Q: What is aluminium hydroxide used for?

A: Aluminium hydroxide (Al(OH)₃) is primarily used as a flame retardant filler in plastics, rubber, and cable jacketing. When heated, it releases water and creates a protective layer of alumina, slowing combustion. It’s also used in pharmaceuticals (as an antacid or vaccine adjuvant) and in water treatment (as a coagulant). A manufacturing business might target polymer manufacturers and construction material makers. 

Q: How is silica gel made from sodium silicate and sulfuric acid?

 A: Silica gel production starts with sodium silicate solution (water glass). When sulfuric acid is slowly added, it neutralizes the silicate and precipitates hydrated silica (a gel). This gel is aged, washed thoroughly to remove sodium sulfate (the byproduct), and then dried. The dried material is activated by heating (200–300°C) to drive off bound water, yielding porous silica. The final product can be crushed into granules or formed into beads.