Zelio Expands to Cuttack with a new EV Manufacturing Plant

Category Electric Scooters

There’s a question we’ve heard a lot over the past two years – from dealers in Odisha & West Bengal who’ve been waiting a week or more for stock to arrive from our Hisar factory: “When are you setting up something closer to us?“

The answer, as of February 2026, is: NOW

Zelio E-Mobility has commissioned a new manufacturing facility in Cuttack, Odisha – our second production unit, and our most important strategic move since we went public.

This isn’t just a new building. It changes how we serve Eastern India, how fast riders get their scooters, and how aggressively we can grow in the region that’s been driving some of our best numbers. Here’s the full story behind the decision – and what it means for our riders, dealers, and the markets we’re building in.

Why Cuttack? Why Now?

The honest answer is that Eastern India didn’t wait for us to decide. Odisha and West Bengal grew into two of Zelio’s highest-performing markets on their own – through word of mouth, through dealers who believed in the product, and through riders who found that a Zelio scooter did exactly what it promised: ran reliably, cost little to maintain, and didn’t drain their savings.

But serving that demand from a single factory in Hisar, Haryana – nearly 1,700 km away – was starting to create real friction. Delivery timelines stretched to a week or more. Dealer inventory ran thin. The supply chain, built for one geography, was being asked to stretch across half the country.

The Cuttack plant solves this cleanly. It puts manufacturing inside the demand zone – helps us deliver faster and efficiently.

What's Changed: The Capacity Picture

Before this expansion, Zelio had a single production facility in Hisar with an installed capacity of 72,000 electric scooters per year. That number has now changed significantly – on two fronts simultaneously.

The Hisar plant didn’t just stay the same while we built elsewhere. Through process-level optimization, installation of extended conveyor systems, and additional machinery, we’ve grown Hisar’s output from 72,000 to 1,20,000 units per year – without building a new facility or a large capital outlay.

The Cuttack plant adds a further 60,000 units per year, focused initially on electric two-wheelers.

Put together: Zelio’s total installed production capacity has grown from 72,000 to 1,80,000 units per annum – a 150% increase. And it happened not through a single massive investment, but through two focused, efficient moves.

The entire Odisha facility was commissioned for under Rs. 3 crore.

We take some pride in that number. A lesser-known truth about scaling a manufacturing operation is that efficiency – how you use what you already have, and how leanly you set up what’s new – matters as much as the headline capacity number.

The Cuttack plant reflects how we think about growth: purposeful, measured, and designed not to burden the business (or our riders) with unnecessary cost.

For Riders, For Dealers

For riders and dealers across Eastern and Southern India, the most immediate change is simpler than any statistic: your scooter will arrive faster.

Previously, a dealer in Odisha waiting on a Zelio shipment was looking at up to seven days from order to delivery. With the Cuttack plant operational, that timeline shortens dramatically – because the product is now being built a few kilometres away, not dispatched from the other end of the country.

Beyond speed, the plant strengthens something that matters equally to serious dealers: inventory confidence. When stock is closer, dealers carry less risk. They can respond to a surge in demand without worrying about a week-long gap. That makes them serve to our riders demand better.

The facility is also expected to generate employment for 60 to 100 individuals across production and operational functions in Odisha – a commitment to the region that goes beyond just using it as a market.

A Word from Our MD

“Eastern India has emerged as one of our strongest growth regions, with customers showing exceptional trust in our products. Setting up the Cuttack facility brings us closer to our riders and dealers, enabling faster deliveries, lower logistics costs and improved serviceability. Notably, this expansion marks an important step in strengthening India’s EV ecosystem and creating long-term value for our customers and partners.”

– Kunal Arya, Managing Director, Zelio E-Mobility

That last line – “creating long-term value for our customers and partners” – is the part we’d like to doubleclick.

For Zelio, this expansion is one chapter in a longer story. The combination of a growing dealer network, two production facilities, a financially healthy balance sheet, and a product built specifically for how India actually rides – that’s the foundation we’re building on.

Find a Zelio Dealer in Eastern India

Our dealer network across Eastern and Southern India is growing alongside the new plant.

Whether you’re in Odisha, West Bengal, Jharkhand, or beyond – visit www.zelioebikes.com to locate your nearest showroom, explore our scooter range, or get in touch with our team.

For dealer partnerships and business enquiries: Call 9254993050