13 July 2026

Zelio E-Mobility Starts Operations at Its New Coimbatore Manufacturing Plant

A few months ago we told you Zelio was planning a new plant in Coimbatore. That plan has now become a running facility. Commercial production started this week, and the timing matters just as much as the announcement did back in March.

Here is what actually changed, what it means for riders in the South, and why a 39,000 sq ft facility on Trichy Road is a bigger deal than its size suggests.

How Quickly This Went From Plan to Reality

When Zelio first spoke about Coimbatore, the plan was to begin setting up the facility in April and have it commercially operational by July. That is exactly what happened. The plant is now assembling electric scooters, and it started production the same day it was formally opened.

That kind of timeline discipline is worth noting on its own. A lot of manufacturing announcements in India slip by months, sometimes years. Zelio moved from plan to production in roughly three months of setup time, which says something about how the company runs its expansion playbook by this point. This is the fourth facility it has commissioned in a similar window, after Ladwa, Patan, and Cuttack.

What the Coimbatore Plant Actually Does

The facility is located on Trichy Road and covers close to 39,000 square feet. It handles scooter assembly along with storage, logistics, and the everyday operational work that keeps a regional supply chain moving. It is not a components factory. It takes Zelio's existing scooter lineup and puts it together closer to where people are actually buying.

That difference is bigger than it sounds. A plant based in Haryana shipping scooters down to Tamil Nadu, Karnataka, Kerala, Andhra Pradesh, Telangana, and South Maharashtra adds days to delivery and adds cost to every unit that travels that far. Building closer to these six markets cuts out a big chunk of that friction in one move.

The plant can produce up to 60,000 units a year at full capacity. Zelio is not pushing it that hard from day one. The initial phase is expected to turn out somewhere between 24,000 and 30,000 units annually, with output scaling up gradually as demand in the region grows. That is a sensible way to ramp a new facility instead of overcommitting early and struggling to hit the number.

What This Adds to Zelio's Overall Manufacturing Capacity

With Coimbatore now live, Zelio's total installed manufacturing capacity across India stands at 2,40,000 units a year. Before this plant came online, that number was 1,80,000. That is a 33 percent jump in one move.

To put the full network in perspective, Zelio now runs four plants. Ladwa in Haryana remains the largest at roughly 2,63,450 square feet. Patan, also in Haryana, adds another 2,52,301 square feet. Cuttack in Odisha, commissioned earlier this year, covers around 30,500 square feet. Coimbatore is the newest addition at close to 39,000 square feet.

Four plants across three states is a meaningfully different company than the one that was running a single facility in Hisar a few years ago. It reflects a manufacturing strategy built around getting closer to demand clusters rather than centralising everything and shipping outward.

How Many People Will Work at the New Plant

The Coimbatore facility currently employs 30 people directly. That number is set to grow past 100 in the coming months, which lines up with Zelio's broader plan to cross 500 employees company-wide by the end of this financial year, up from around 260 today.

The roles being filled here are not just factory floor positions. They include plant leadership, production planning, quality control, and the kind of operational staff that keeps a new facility running smoothly as it scales. For Coimbatore specifically, this hiring is happening at the same time the plant is being commissioned for larger-scale output, so the workforce is growing alongside the production ramp rather than after it.

Why South India, and Why Now

Kunal Arya, Managing Director of Zelio E-Mobility, has been consistent about the reasoning behind this plant since it was first announced. His view is that South India represents a genuine growth corridor for the company, driven by rising demand for electric mobility and strong underlying market potential in the region. He has framed the Coimbatore facility as a strategic move to tighten the supply chain and support the pace at which Zelio's dealer network is expanding in the South.

That dealer expansion is real and ongoing. Zelio currently operates through more than 400 dealerships spread across 25-plus states, and the plan for the coming year is to push that past 550, with South India and the North-East as the two regions getting the sharpest focus. A local manufacturing base in Coimbatore is the natural companion to that dealer growth. More outlets without local supply just means longer waits for customers and higher freight costs for the company. Coimbatore closes that gap for six states in one go.

Planning to Buy a Zelio Scooter in South India? Here's What You Should Know

For a rider in Chennai, Bengaluru, Kochi, Hyderabad, or Coimbatore itself, the practical impact of this plant shows up in two places over the coming months. Delivery timelines to dealerships in these markets should shorten as inventory starts moving from a facility that is days closer rather than a full country away. And as the plant scales toward its 60,000 unit capacity, dealer stock availability across these states should improve, meaning fewer waitlists for popular models.

The scooters coming out of Coimbatore are built to the same manufacturing standards and quality protocols as every other Zelio plant. This is not a lower-spec regional line. It is the same product, assembled closer to home for southern buyers.

If you want to check current models and pricing, the Zelio dealer locator is the fastest way to find your nearest showroom as the network in the South continues to expand.

For the latest on-road prices across Zelio's lineup, see the battery scooty price list.

How This Fits Into Zelio's Larger Growth Story

Coimbatore is not an isolated move. It follows the Cuttack plant that came online earlier this year, and it lines up with a company that reported revenue of Rs 313.68 crore in FY26, up 81.8 percent over the year before, while staying profitable the entire time. That combination of manufacturing expansion funded by actual business performance, rather than a story built purely on investor capital, is what separates this expansion from a lot of the noise in the wider Indian EV space right now.

A new plant commissioned every few months, a workforce doubling in the same year, and a dealer network aiming to cross 550 outlets are not three separate announcements. They are one company scaling in a coordinated way, and Coimbatore going live this month is simply the latest piece of that falling into place.

Sources

Zelio Team

Innovation Department

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Zelio Eeva Now Comes in 4 Colours - Here's What Else Changed

Electric Scooters

7/14/2026

Zelio Eeva Now Comes in 4 Colours - Here's What Else Changed

If you liked the Zelio Eeva but always wanted more colour options, you now have them. The Eeva is available in four colours, along with a few small updates that make it feel fresher without changing what already worked well. Here is a full look at what's new, what stayed the same, and where it fits if you are shopping for a daily scooter right now. The 4 New Colours The Eeva now comes in white and silver dual tone, a deep green paired with black, a clean all-white finish, and a bold blue. That is a good range of options for a scooter in this price bracket. Most electric scooters at this price stick to two or three safe colours. Zelio has picked four options that feel distinct from each other, not just four shades of the same idea. If you park this scooter outside your college , your office , or your building every day, having a colour that actually feels like yours makes a small but real difference. What's New Besides the Colours The bigger change is the digital speedometer. Earlier versions of the Eeva used a simpler display. Now every rider gets a proper digital speedometer, which makes checking your speed and battery level a lot easier at a glance, especially in traffic when you do not want to be squinting at a small dial. Zelio describes this version as "ideal for all types of riders," and going by the spec sheet, that holds up. The scooter feels light and manageable whether you are riding for the first time or you have been on scooters for years. Zelio Eeva - Specs, Price and What You Get Zelio Eeva | Price: Rs 55,834 (60V/32AH Lead Acid) | Range: 60-90 km | Motor: 60/72V BLDC | Licence: No Rs 55,834 gets you a scooter that covers all the basics well. The Eeva N runs on a Gel battery (60V or 72V, 32AH or 42AH) or a Lithium battery (60V/30AH or 74V/32AH). The Lithium option costs a bit more but charges faster and lasts longer over time. Either way, a few simple charging habits make a real difference, and our guide on extending your electric scooter's battery life covers what to do and what to avoid. The 60/72V BLDC motor is smooth and low maintenance, built for everyday city riding rather than speed. Since it is a low speed scooter, it also falls under the no licence, no RTO registration category, so you can ride it home the same day you buy it, no paperwork involved. Our low speed vs high speed electric scooter guide explains exactly how that classification works if you want to know more. Running cost comes to roughly 1.5 units of electricity per full charge, which makes it one of the cheapest ways to get around in India right now. You get drum brakes on both wheels, 90-90/12 tyres front and rear for a stable ride, and hydraulic suspension on both ends that handles potholes and speed breakers noticeably better than basic spring setups. Along with that, the Eeva N comes with a centre lock and anti-theft alarm, a USB charging port, a proper footrest, keyless drive, an LED headlamp, and more foot space than you would expect at this price. All of it comes with Zelio's standard 2 year warranty on the motor, controller, and frame. Price is ex-showroom, Haryana and Punjab, June 2026. Explore Zelio Eeva N For the latest on-road prices across Zelio's lineup, see the battery scooty price list . Who Should Actually Buy This If your daily ride falls somewhere between 15 and 30 kilometres, the Eeva's 60 to 90 km range on a single charge means you are not thinking about charging every single day. Students, working professionals with a short office commute, and anyone who wants a scooter that does not need a licence will find this an easy choice. For a broader look at what makes a scooter genuinely good for everyday commuting, our guide to the best electric scooter for daily commute is worth reading, and if you want to compare prices across regions, our electric scooter price list for Delhi is a good place to check. Being a low speed scooter also means less to deal with overall. No RTO visits, no licence tests, no road tax. You buy it, charge it at home, and ride. Zelio has 360+ authorised dealers across 25+ states. Use the dealer locator to find your nearest Zelio authorised dealer. Then Walk in, take a test ride, and find the right scooter for your daily commute.

Electric Scooter Insurance in India - Do You Need It?

Electric Scooters

7/10/2026

Electric Scooter Insurance in India - Do You Need It?

If your scooter is a high-speed, RTO-registered model, insurance is not optional. It is mandatory by law to have insurance for that scooter, But If your scooter is a low-speed model under 25 km/h that needs no licence and no registration, insurance is not legally required. But "not required" and "not needed" are two very different things, and that gap is where most buyers get confused. We build both kinds of scooters at Zelio, so we get this question at almost every showroom conversation. The Legal Position - What the Law Actually Says India splits electric two-wheelers into two categories under the Central Motor Vehicles Rules, and your insurance obligation depends entirely on which category your scooter falls into. High-speed electric scooters (motor above 250W or top speed above 25 km/h) are treated exactly like a petrol scooter under the Motor Vehicles Act. Third-party insurance is compulsory. Riding without it is a punishable offence, and traffic police can fine you, impound the vehicle, and in an accident you are personally liable for damages that a valid policy would otherwise have covered. Our low speed vs high speed electric scooter guide breaks down exactly how these two categories are defined and what changes between them. Low-speed electric scooters (250W or less, 25 km/h or less) are classified as non-motorised vehicles. No licence, no RTO registration, no road tax, and no mandatory insurance. Every standard Zelio model falls in this category. Our RTO fees guide for electric two-wheelers covers the full registration picture if you want to understand why this exemption exists in the first place. That is the legal answer. Now here is the part that actually matters for your decision. Which Zelio Models Need Insurance and Which Don't Since this is the question we get asked most directly, here is the straight breakdown by model. No insurance legally required (low-speed, exempt category): Eeva , Eeva Eco , Eeva Eco LX , Eeva Eco ZX , Eeva ZX , Eeva ZX+ , Little Gracy , Gracy , Gracy i , Gracy+ , Gracy Pro , Legender , Legender+ , Legender+ Premium , Logix , Loader , X-Men+ and X-Men 2.0 are all built to run at or under 25 km/h with a motor of 250W or less. Every one of these qualifies as a non-motorised vehicle under CMVR, which means no licence, no RTO registration, no road tax, and no mandatory insurance. This covers the entire standard Zelio lineup. Insurance legally mandatory (high-speed, registered category): Mystery is Zelio's only high-speed model. Its motor and top speed cross the CMVR exemption limits, which means it is classified as a motor vehicle under the Motor Vehicles Act. If you ride a Mystery, you must have a valid driving licence, RTO registration and at minimum third-party insurance before taking it on public roads. Skipping insurance on this model is not a grey area. It is a legal requirement, same as any petrol scooter. For the latest on-road prices across Zelio's lineup, see the battery scooty price list . Why "Not Mandatory" Does Not Mean "Skip It Without Thinking" This is where most articles on this topic stop short. They tell you insurance is optional for low-speed scooters and move on. We think that leaves out the one detail that should actually shape your decision. If you are riding a low-speed scooter with no insurance and you accidentally hit a parked car, damage someone's shop shutter, or injure a pedestrian, the fact that your scooter is legally exempt from insurance does not make you exempt from paying for the damage. You are personally liable. There is no insurer standing behind you. If the claim runs into lakhs, and vehicle damage or medical claims genuinely can, you are paying that out of your own pocket, not an insurance company's. This is not a scare tactic. It is simply how liability works. The exemption removes a legal requirement to hold a policy. It does not remove your responsibility if something goes wrong on the road. For a scooter that mostly does 15-20 km/h through a colony or a market lane, the odds of a serious incident are genuinely low. But low odds are not zero odds, and the one time it matters is exactly the time you wish you had covered it for a few hundred rupees a year. Warranty Is Not Insurance - A Confusion Worth Clearing Up We hear this mix-up often enough that it deserves its own section. A 2-year warranty on your scooter's motor, controller, and frame protects you against manufacturing defects. If a part fails because of how it was built, the warranty covers the repair or replacement. It does not cover theft. It does not cover accident damage. It does not cover fire, flood, or a scooter stolen from outside your building. Warranty and insurance solve two completely different problems, and treating your warranty card as if it is also your insurance policy is a mistake that only becomes obvious the day something actually happens. If your scooter is stolen tomorrow, your warranty is worthless in that situation. Only insurance, or the money in your own pocket, replaces it. What Voluntary Insurance Actually Costs for a Low-Speed Scooter For a scooter priced between Rs 50,000 and Rs 80,000, a standalone fire and theft policy typically costs somewhere between Rs 600 and Rs 1,200 a year, depending on the insurer and your city. A more complete comprehensive-style policy covering accidental damage as well usually falls between Rs 1,200 and Rs 2,500 annually, again depending on your scooter's value and where you live. Put that against the price of the scooter itself. On a Rs 58,159 Zelio Gracy i, a full year of comprehensive-style protection costs roughly what you would spend on two tanks of petrol for a comparable commute. It is a genuinely small number next to what it protects. Insurers do not currently offer these policies specifically branded for "low-speed EVs" in every market, since the category is newer and the policy language is still catching up. In practice, most riders get this cover through a general asset or personal accident add-on, or through a standalone two-wheeler policy that some insurers extend even to non-registered low-speed vehicles on request. It is worth calling two or three general insurers directly and asking, because coverage availability does vary. What Happens If Your Scooter Is Stolen and You Have No Insurance This is the scenario every rider without insurance eventually has to face, and it plays out simply. The scooter is gone. There is no registration certificate to file against, since low-speed scooters are not registered. You can file a police complaint using your purchase invoice and the chassis or motor number, which helps if the scooter is later recovered, but there is no payout coming. The replacement cost comes entirely from you. If you had a fire and theft policy in place, this is exactly the situation it was built for. You file a claim with your invoice, the FIR copy, and any other documents the insurer asks for, and you get compensated based on the scooter's current insured value. High-Speed Electric Scooter Insurance - What It Actually Involves If you are riding one of Zelio's high-speed models, insurance is not a choice, so the more useful question is what it costs and what to look for. Third-party insurance is the legal minimum and covers damage or injury you cause to someone else, not damage to your own scooter. For most electric scooters in the mid-price range, third-party premiums typically run a few hundred rupees to around a thousand rupees a year, set by IRDAI-mandated slabs rather than by individual insurers. Comprehensive insurance adds coverage for your own scooter against accident damage, theft, and fire, on top of the mandatory third-party portion. This costs more, usually a percentage of your scooter's insured value, but it is the difference between paying for your own repair bill and having it covered. Whichever level you choose, always carry your registration certificate, your driving licence, and your valid insurance policy while riding a high-speed scooter. All three get checked during routine stops, and missing any one of them results in a fine. Who Should Seriously Consider Voluntary Insurance Not every low-speed scooter owner needs to rush out and buy a policy, but a few situations make it a genuinely smart call rather than an optional extra. You park on the street rather than inside a gated society. Theft risk goes up meaningfully when the scooter sits outside overnight without any building security. You ride in dense city traffic daily. More traffic exposure means more chances of a minor collision, even at 25 km/h. Your scooter is on the higher end of the price range. A Rs 75,000+ lithium model losing to theft or fire is a bigger financial hit than a Rs 45,000 entry model, and the insurance cost difference between the two is small in comparison. You are the sole earner relying on the scooter for daily commute or delivery work. Losing the scooter without a replacement plan directly hits your income, not just your convenience. If none of these apply and your scooter stays inside a secure compound with light daily use, the case for voluntary insurance is weaker, though never zero. A Quick Way to Decide Ask yourself three questions. Where does the scooter sleep at night? How much would replacing it cost you today, in cash, with no notice? And how would you feel if it never came back? If the answers make you uneasy, a few hundred rupees a year for peace of mind is not a hard decision. For daily commuters using a Zelio scooter to save on fuel every month, as covered in our best electric scooter for daily commute guide , protecting that saving with a small annual premium is a sensible extension of the same financial thinking that led to buying an electric scooter in the first place.

Zelio E-Mobility Plans to Double Its Workforce in FY27

EV News

7/7/2026

Zelio E-Mobility Plans to Double Its Workforce in FY27

Zelio E-Mobility, the Hisar-based electric two and three-wheeler manufacturer, has announced it will more than double its workforce during the current financial year. The company currently has around 260 employees spread across its manufacturing facilities in Hisar, Bhubaneswar, and Coimbatore. The plan is to take that number past 500 before the end of FY27. This is not a speculative growth target. It is a response to actual business performance. Zelio reported revenue of Rs 313.68 crore in FY26, an 81.8 percent increase over the Rs 172.19 crore it posted the year before. The company has been profitable since inception and has recorded a revenue CAGR of approximately 121 percent over the last four years. The hiring push is the company catching up to where the business already is. Where the New Hires Are Going The expansion is spread across three locations, each with a specific purpose. Hisar - Zelio's headquarters and primary manufacturing base in Haryana. The bulk of the hiring here will focus on production, quality control, and core manufacturing operations. Bhubaneswar - Zelio's facility in Odisha supporting the East India and North-East expansion push. Coimbatore - The newest facility in the lineup. Coimbatore is still being commissioned and ramped up, which makes it the most significant of the three locations in terms of what the hiring signals. A hundred new employees at a facility that is just scaling up means Zelio is serious about South India as a growth market. The roles being filled span manufacturing, R&D, quality, production planning, zonal sales leadership, and after-sales service. These are not temporary or support hires. They are the people who run plants, lead sales territories, and keep the service network functional as dealerships grow. What Our CEO Said Divyanshu Agarwal, CEO of Zelio E-Mobility, explained the thinking behind how the company approaches expansion: "Our expansion is not only focused on manufacturing growth but also on building strong local ecosystems in each region we operate in, ensuring long-term value creation through employment and skill development." That framing matters. Zelio is not building factories and shipping in management from headquarters. The plan is to hire locally in Bhubaneswar and Coimbatore, creating jobs and skills in those markets specifically. For a company entering new geographies, that approach tends to build stickier relationships with local governments, dealers, and customers than a centralized model does. Divyanshu also made the point that this has been consistent with how Zelio has operated since its founding: "Since the beginning, Zelio has always been a people-first company. Wherever we enter, whether a state or a city, our focus is to create meaningful job opportunities and contribute to local employment." The Business Context Behind the Hiring Zelio listed on the BSE SME platform in October 2025. The IPO raised Rs 78.34 crore, including a fresh issue of Rs 58.84 crore and an offer for sale of Rs 15.50 crore. The IPO was subscribed 1.5 times overall. Since listing, the company has continued to perform. The FY26 revenue of Rs 313.68 crore represents the strongest year the company has had, and it came after years of consistent profitability that set Zelio apart from several larger EV peers that are still reporting losses. The dealership network currently stands at 400+ outlets across 25+ states. The target for FY27 is 550+ dealerships, with a specific focus on South India and the North-East. The Coimbatore hiring directly supports the South India push, and the Bhubaneswar hires support the East and North-East strategy. For a company to expand its dealer network to 550 locations and maintain after-sales quality across that footprint, it needs the backend workforce to match. That is the practical reason behind the 500+ headcount target. Why This Matters Beyond Zelio Zelio's expansion follows a pattern that tells you something about where the Indian EV market is heading, particularly in the slow-speed electric scooter segment. The brands seeing the fastest growth in this segment are not the ones with the biggest advertising spends. They are the ones building manufacturing depth, dealer width, and service reliability simultaneously. A dealer in a tier-2 city who cannot get spare parts within 48 hours or reach a service professional by phone becomes a liability, not an asset. Zelio's hiring of after-sales professionals and zonal sales leaders alongside plant staff reflects an understanding of this. The 121 percent revenue CAGR over four years, combined with consistent profitability, also tells a different story than the wider EV narrative in India, where many companies are still in investment mode and reporting operating losses. Zelio has been growing while keeping the business in the black, which gives the current expansion a more stable foundation than if it were funded purely by external capital. With 2 lakh+ riders already on Zelio scooters across India and a lineup of 19 models starting at Rs 47,784, the workforce expansion is ultimately about making sure the company can serve what it has already sold, and confidently sell more. For the latest on-road prices across Zelio's lineup, see the battery scooty price list . What Roles Zelio Is Hiring For Based on the official announcement, the hiring covers: - Plant heads and production planning specialists - R&D and quality control professionals - Zonal sales managers and regional sales leaders - After-sales service and customer support professionals - Manufacturing floor staff at Hisar and Coimbatore If you are looking to be part of Zelio's expansion, The Zelio E-Mobility careers is the right place to start. Sources Zelio E-Mobility to Double Workforce as EV Expansion Gains Pace Across India - EMobility+, 2026 Zelio set to cross 500 employees in FY27 - HR Katha, 2026 Zelio E-Mobility to Double Workforce to Over 500 Employees - Manufacturing Today India Zelio E-Mobility Plans to Double Workforce Following Strong Revenue Growth - Economic Times Auto, 2026 Zelio E-Mobility to Double Workforce, Expand Employee Strength Beyond 500 - GearFliq