What is a helmet project report?
A helmet project report is a detailed project report (DPR) for a unit that moulds ABS shells and EPS liners and assembles ISI-marked two-wheeler helmets. It sets out the process, moulds and machines, raw materials, BIS licensing, project cost, means of finance, five-year projections, DSCR and break-even that a bank needs to judge the loan.
Entrepreneurs and existing plastic moulders use it to size the plant and apply for a term loan; lenders and CAs use it to test whether the unit can repay.
Also known as: project report on helmet, helmet manufacturing DPR, helmet business plan, two-wheeler helmet plant project report.
What a bank looks for in a helmet project
A credit officer reads a helmet report for four numbers first. These are the values in our sample report and why each one gets questioned.
This is the price to distributors, before GST and well below the printed MRP. Revenue built on retail prices is the first thing a bank cuts.
ABS, EPS, visors, straps and paint take about half of every rupee of sales. A much lower share usually means rejections were left out.
Distributors and dealers expect two months of credit. Debtor days drive the cash credit limit more than raw material stock does.
DSCR is the cash available to repay the loan divided by the repayment due. Year 2 is the tightest year, when full instalments start.
Values are the assumptions in our illustrative sample. Your report uses figures for your capacity, product mix and market.
Helmet manufacturing plant cost in India
Cost depends on how many shell sizes you mould, whether you make your own EPS liners and visors, and whether you own the land. The large tier is the unit in our sample report; the other two are indicative ranges.
Small unit
₹50–90 lakh
About 200–400 helmets per day, one shell moulding machine
- Machinery and moulds₹30–55 lakh
- Shed fit-out (rented)₹5–12 lakh
- Working capital margin₹8–15 lakh
Buys liners and visors; PMEGP only within its ₹50 lakh limit
Mid-size unit
₹2.5–4.5 crore
About 500–800 helmets per day, own EPS liners
- Machinery and moulds₹1.2–2.2 crore
- Land and building₹0.8–1.6 crore
- Working capital margin₹25–45 lakh
MSME term loan, often with CGTMSE cover
Large unit
₹705.51 lakh
1,200 helmets per day, 3,60,000 helmets per year
- Plant and machinery₹319.90 lakh
- Land and building₹252.31 lakh
- Working capital margin₹60.24 lakh
Term loan ₹529.13 lakh (75%), promoter ₹176.38 lakh
Small and mid-size ranges are indicative. Mould count, machine make and land rates move the cost more than anything else.
Helmet project cost and profitability in the sample
The sample report models a 1,200 helmets per day unit working 300 days a year, starting at 60% capacity and reaching 80% in Year 5. Helmets are sold at ₹547 each, ex-factory and before GST.
| Land and site development | 70.86 |
|---|---|
| Building and civil works | 181.45 |
| Plant and machinery | 319.90 |
| Other fixed assets | 32.25 |
| Contingencies | 25.07 |
| Preliminary and pre-operative | 15.74 |
| Working capital margin | 60.24 |
| Total | 705.51 |
| Promoter's contribution (25%) | 176.38 |
|---|---|
| Term loan from bank (75%) | 529.13 |
| Cash credit limit (separate) | 180.71 |
| Total project cost | 705.51 |
Term loan at 10.5% with a 6-month moratorium and 54 monthly instalments. All figures are illustrative.
Helmet manufacturing process, step by step
A helmet is three moulded parts, the shell, the EPS liner and the visor, joined with bought-in straps and padding. Small units often buy liners and visors and mould only the shell.
- Shell moulding
ABS granules are dried to remove moisture, then injection moulded into shells, with a separate mould for each shell size.
- Trimming and buffing
Gates and flash are cut away and vent holes drilled, then the shell is buffed so primer bonds without peeling.
- Painting and graphics
Shells are primed, spray painted, fitted with decals and lacquered in a dust-free booth, then baked to cure the coat.
- EPS liner moulding
Polystyrene beads are pre-expanded and fused with steam in a mould; liner density decides how much impact the helmet absorbs.
- Visor moulding
Polycarbonate is moulded into clear or tinted visors, then coated to resist scratches.
- Assembly
The liner is bonded into the shell, and padding, chin strap and visor are fitted by riveting and stitching.
- Batch testing and marking
Helmets from each batch are tested for shock absorption, penetration and strap retention before the ISI mark is applied and they are packed.
Raw materials for helmet making
ABS for the shell is the biggest single input, but bought-in straps, buckles and paint together cost more. Plastic granule prices follow crude oil, so a sound report tests a rise in ABS and polycarbonate prices.
| Raw material | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| ABS granules for outer shell | 32% | 222.58 |
| EPS beads for impact liner | 10% | 69.55 |
| Polycarbonate granules for visor | 12% | 83.47 |
| Chin straps, buckles and D-rings | 16% | 111.29 |
| Comfort padding fabric and foam | 14% | 97.38 |
| Paint, lacquer and decals | 16% | 111.29 |
| Total | 100% | 695.56 |
Helmet making machines and moulds
The shell moulding machine is the largest item in the sample. Moulds are the cost most often under-budgeted, because every shell size and every liner and visor needs its own.
| Machine | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Injection moulding machine for shells | Moulds ABS shells | 102.37 |
| Injection moulding machine for visors | Moulds polycarbonate visors | 38.39 |
| EPS pre-expander and steam moulding machine with boiler | Expands beads and moulds liners | 51.18 |
| Shell, liner and visor moulds | One set per size and model | 44.79 |
| Spray paint booth with baking oven | Paints and cures shells | 25.59 |
| Trimming, buffing and drilling equipment | Finishes shells for painting | 12.80 |
| Assembly line with stitching and riveting machines | Fits liner, padding and straps | 15.99 |
| Helmet testing equipment | Impact, penetration and retention tests | 28.79 |
| Total plant and machinery | 319.90 | |
Costs are the sample report's estimates for a 1,200 helmets per day line. Get current quotations before you finalise.
Who buys helmets from a new manufacturer?
Demand comes from two-wheeler riders, because helmets are compulsory for riders on Indian roads and must be replaced after a fall or with wear. Known brands lead retail shelves, so a new unit usually starts with buyers who order in bulk to a specification.
- Two-wheeler dealers who bundle a helmet with each new vehicle
- Helmet and auto accessory distributors in tier 2 and tier 3 towns
- Delivery and ride-hailing fleet operators
- Private-label buyers who sell under their own brand
- Retail chains and online sellers
Where a new unit wins: helmets are bulky for their value, so freight and carton volume matter. A unit near its distributors, with two or three popular shell sizes and quick colour changes, can match larger brands on delivered cost.
BIS licence and approvals for a helmet unit
The BIS licence decides when you can start selling, so plan it before commercial production. As of October 2026 these are the main approvals.
| Product standard | IS 4151:2015, Protective helmet for two-wheeler riders, with ISI marking under a BIS licence |
|---|---|
| Quality Control Order | Helmet for Riders of Two Wheeler Motor Vehicles (Quality Control) Order, 2020, in force from 1 June 2021; making or selling uncertified helmets is an offence under the BIS Act, 2016 |
| Industrial safety helmets | A separate product under IS 2925:1984, covered by the Helmet for Police Force, Civil Defence and Personal Protection (Quality Control) Order, 2023; it needs its own licence |
| Pollution board consent | Consent to establish and operate from the State Pollution Control Board. Plastic products from virgin plastic are in CPCB's 2020 green list, but a paint shop and boiler can change the category; confirm with your state board |
| Business registration | Udyam (MSME) and GST registration, plus a trademark if you sell under your own brand |
| Factory and fire | Factory licence where the worker threshold applies, and a fire NOC, since paint solvents and EPS are stored on site |
Mistakes that weaken a helmet project report
- Sales from the first month
Under the Quality Control Order you cannot sell until the BIS licence is granted. The report should leave time for the licence before revenue starts.
- One mould budget for every size
Most buyers want at least two or three shell sizes, each with matching liner moulds. Costing a single mould set under-states machinery.
- No allowance for paint rejects
Dust, runs and peeling send shells back for rework or scrap. Saleable output must be lower than moulded output.
- Mixing two-wheeler and industrial helmets
They follow different standards and licences. One report that blends both confuses the capacity, price and approvals.
- Ignoring buyer credit
With 60 days of credit to dealers, a thin cash credit limit leaves the unit short of ABS and straps in its first year.
How NPCS helps you set up a helmet unit
- Product and size mixChoose open-face or full-face models, shell sizes and daily output for your buyers.
- Machines and mouldsCompare moulding machines, EPS lines and mould sets, and collect quotations.
- Bank-ready project reportProjections, DSCR and working capital in the format your lender expects.
- BIS and plant layoutThe approvals list for IS 4151 and your state, with a layout for moulding, painting and testing.
NPCS's client list includes 2 helmet assignments and 28 in automotive components, and the NPCS project team, led by founder Ajay Kumar Gupta, has prepared project reports since 1994.
What's inside the helmet sample report
- Introduction
- Uses and applications
- Market potential
- Manufacturing process
- Raw materials
- Plant and machinery
- Land, building and utilities
- Manpower
- Licences and approvals
- Project cost and means of finance
- Working capital
- Projected profitability
- Cash flow statement
- Projected balance sheet
- Depreciation
- Term loan repayment
- Debt service coverage
- Break-even analysis
- Financial ratios
- Key assumptions
- Conclusion
- Monthly loan repayment schedule
19 pages, five-year projections, illustrative figures.
Open sample reportFree sample or a report for your project?
| What you get | Free sample | NPCS report for your project |
|---|---|---|
| Capacity and location | Typical unit | Your capacity, site and state |
| Figures | Illustrative | Built on current prices and quotations |
| Machinery suppliers and quotations | No | Yes |
| Market survey for your region | No | Yes |
| Bank or scheme format (PMEGP, term loan) | No | Yes |
| Use for a loan application | No | Yes |
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Helmet project report: frequently asked questions
How much does it cost to start a helmet manufacturing unit in India?
A small unit moulding 200–400 helmets a day needs roughly ₹50–90 lakh in a rented shed, and a 500–800 per day unit about ₹2.5–4.5 crore with land and building. Our sample report models 1,200 helmets per day at ₹705.51 lakh. These are indicative figures; your report works out the cost for your capacity, sizes and location.
What raw materials are used to make a two-wheeler helmet?
The shell is moulded from ABS or polycarbonate granules, the impact liner from expanded polystyrene (EPS) beads and the visor from optical-grade polycarbonate. Bought-in parts are chin straps, buckles, D-rings, comfort padding, paint, lacquer and decals. In our sample report ABS is the largest single item at 32% of raw material cost.
Is ISI certification mandatory for helmets?
Yes. Since 1 June 2021 every helmet for two-wheeler riders made or sold in India must meet IS 4151:2015 and carry the ISI mark under a BIS licence. The rule comes from the Helmet for Riders of Two Wheeler Motor Vehicles (Quality Control) Order, 2020. Selling without the licence is an offence under the BIS Act, 2016.
Is helmet manufacturing profitable?
In our illustrative sample, a 1,200 helmets per day unit earns a 22% return on investment in Year 3. It breaks even at about 42% of capacity and pays back in about 3.6 years. Real profit depends on shell weight per helmet, paint rejection rates, the share of full-face models and the credit you give dealers.
Can I get a PMEGP loan for a helmet unit?
Only if the whole project stays within the PMEGP limit of ₹50 lakh for manufacturing, which suits a lean unit with one shell moulding machine in a rented shed. PMEGP gives a margin-money subsidy of 15–35% of project cost. Larger helmet units usually take an MSME term loan, often with CGTMSE guarantee cover for collateral-free credit.
Helmet ka business kaise shuru kare?
Start by choosing the helmet type and daily output, then work out the moulds you need for each shell size. Apply for the BIS licence to IS 4151 early, because you cannot sell without it. Get a project report with machinery quotations, cost and DSCR, take it to your bank, then set up the shed, power and pollution consent.
Is the helmet project report PDF free, and can I use it for a loan?
The sample is free to view and download. It is an illustrative report that shows the format and depth of an NPCS report; its figures are representative and not based on a real project, so it should not be submitted to a bank. For a loan, NPCS prepares a report for your own capacity, location and loan scheme.
Sources and references
- Proper implementation of the Quality Control Order on helmets (letter to District Collectors, 25 July 2024)Department of Consumer Affairs, Government of India, checked Oct 2026
- Helmet for Police Force, Civil Defence and Personal Protection (Quality Control) Order, 2023Gazette of India, DPIIT, checked Oct 2026
- Prime Minister Employment Generation Programme (PMEGP)MSME Department, Government of Uttar Pradesh, checked Oct 2026
- Credit Guarantee Fund Trust for Micro and Small EnterprisesCGTMSE, checked Oct 2026
- Green category industries as per CPCB revised list 2020Puducherry Pollution Control Committee, checked Oct 2026
The NPCS project team, led by Ajay Kumar Gupta
This page and its sample report are prepared and reviewed by the NPCS project team, which has written techno-economic feasibility studies and detailed project reports since 1994.
Ajay Kumar Gupta founded Niir Project Consultancy Services (NPCS) and leads the organisation. With 40 years of experience in MSME project consulting, he has built the team that has delivered more than 28,000 project reports for clients worldwide, helping entrepreneurs plan and finance profitable manufacturing businesses.
- Published
- Last updated
- Next review
- Oct 2027
- Reviewed by
- NPCS project team
This page is reviewed every 12 months, or sooner when scheme limits, GST rates, BIS rules or pollution categories change. The sample report is illustrative: its figures are generated from industry-typical ratios for a unit of this size, checked so every statement balances, and are not taken from any client project.