Ultraviolette to Invest Rs 779 Crore in New BIGGA Factory in Hosur

Ultraviolette Automotive has announced a major manufacturing expansion, revealing plans to establish a new production facility in Hosur, Tamil Nadu. Named the BIGGA Factory, which stands for Big Global Ambition, the plant represents a capital commitment of Rs 779 crore over the next five years. The facility will initially focus on manufacturing the company's upcoming Tesseract electric scooter, scheduled for release in early 2027, before expanding to support a broader portfolio of electric two-wheelers.

The establishment of this factory marks a transition for the Bengaluru-based startup, which has previously focused on low-volume, high-performance electric motorcycles. By scaling up its manufacturing footprint, Ultraviolette aims to address both domestic demand and international markets. The new facility will operate in tandem with the company's existing manufacturing plant in Bengaluru, Karnataka, which will continue its regular operations.

The Rs 779 crore investment will be deployed in a phased manner over a five-year horizon. In its initial phase, the BIGGA Factory is designed to achieve an annual manufacturing capacity of 2.5 lakh (250,000) vehicles. The underlying infrastructure is engineered to scale up to 5 lakh (500,000) units per year as market demand intensifies.

Ultraviolette co-founder and CEO Narayan Subramaniam explained that the current investment is specifically allocated to guide the facility through its initial 2.5 lakh unit capacity. "So the amount we've spoken about now (Rs 779 cr) is for the next five years, which is through seeing the entire facility scale to 250,000 units. So at this point, I would not want to comment on what the next phase of scale up is. In fact, the next phase would probably be even more aggressive because the EV market is growing," Subramaniam stated in an interview with PTI.

The BIGGA Factory will be situated at the SIPCOT Industrial Park in Shoolagiri, Hosur, with the land allotment being facilitated by the Government of Tamil Nadu. The choice of Hosur is highly strategic, leveraging the region's mature automotive manufacturing ecosystem. The location offers immediate access to an established supplier network and is situated close to Ultraviolette's primary research and development headquarters in Bengaluru.

Niraj Rajmohan, co-founder and CTO of Ultraviolette, emphasized the logistical and operational benefits of the site. "Hosur is a key manufacturing hub with a well-established automotive ecosystem, significant supply-chain advantages and close proximity to Ultraviolette's R&D operations and existing supplier network," Rajmohan noted. He stated that these strategic benefits, combined with the precision and manufacturing agility of the new factory, will allow the company to deliver its vehicles to Indian and global buyers while maintaining strict quality standards.

To manage high-volume production, Ultraviolette is equipping the BIGGA Factory with Industry 4.0 manufacturing technologies. Central to these operations is a Manufacturing Execution System (MES) designed for real-time production tracking and component traceability. The facility will also implement digital lean manufacturing protocols and digital quality systems to minimize production defects.

Automation will play a prominent role on the assembly floor. The company plans to deploy collaborative robots, or cobots, to assist human workers with sorting, welding, and assembly tasks. Additionally, the plant will feature automated assembly error-proofing systems and vision-based inspection systems to verify build quality. Every vehicle manufactured at the site will undergo evaluation on a dedicated on-site test track before being cleared for dispatch.

The expansion aligns with a major shift in Ultraviolette's product strategy. While the company is known for its high-performance electric motorcycles, such as the F-Series, X-Series, and Shockwave, its 2027 product roadmap indicates a diversification into more mainstream segments. The BIGGA Factory will support a future portfolio spanning Sports, Crossover, Cruiser, Street, and Scooter categories.

The company's roadmap reveals plans to launch two new electric scooters starting in the first quarter of 2027. One of these is the Tesseract, while the other appears to be a rounded, family-oriented scooter. This move places Ultraviolette in direct competition with established players and emerging startups in the mainstream Indian EV market. Competitors like Ather Energy with its Konarc, Simple Energy with its Wave range, and legacy manufacturers like TVS, Bajaj, and Vida are already competing heavily in this high-volume segment.

Beyond manufacturing capacity, the BIGGA Factory is expected to have a notable economic impact on the region. The initial phase of operations is projected to create approximately 2,000 job opportunities. This workforce is expected to scale further over the next five years as production volumes increase toward the facility's maximum capacity.

The new plant will not replace Ultraviolette's original footprint. The existing Bengaluru facility will continue to handle its current manufacturing and development tasks. According to Subramaniam, maintaining both facilities strengthens the company's long-term manufacturing and technology footprint in India, allowing the Bengaluru site to work in tandem with the high-volume Hosur plant.

The next immediate milestone for Ultraviolette is the completion of the initial construction phase at the Shoolagiri site, followed by the installation of the Industry 4.0 assembly lines and the on-site test track. The company is preparing for the commercial launch of the Tesseract electric scooter in early 2027, which will serve as the first vehicle to roll off the BIGGA Factory's production lines. Further details regarding the specifications and pricing of the upcoming 2027 scooter models are expected to be disclosed closer to their official launch dates.