The story of Avlight Automotives Pvt. Ltd. is a classic example of how commitment to engineering excellence, customer focus and continuous improvement can transform a small start‑up into a trusted global supplier. Over nearly three decades, the company has expanded from a modest plastic‑moulding operation in northern India to a multi‑plant organisation supplying precision lighting systems and plastic components to original‑equipment manufacturers (OEMs) and Tier‑1 partners across India, North America, Europe and China. This article traces Avlight’s journey from its foundation in 1996 to its current status as a respected brand in automotive lighting and injection‑moulded components, highlighting key milestones, strategic decisions and the values that underpin its success.
Avlight Automotives was founded in 1996 by two first‑generation industry professionals – Mr. Anil Anand and Mr. Rajan Sharma. With decades of collective experience in tier‑1 supply chains, they recognised a gap in India for reliable suppliers of automotive lighting equipment, plastic injection moulds and moulded plastic items. Setting up operations in the industrial hub of Faridabad, Haryana, the founders pursued a vision of precision engineering and customer‑centric service at a time when India’s automotive industry was still maturing.
From the outset, Avlight emphasised quality, innovation and process control. The company invested early in well‑maintained injection‑moulding machines and tool‑room equipment to deliver high‑precision plastic components. These parts catered to clients in the automotive and consumer durables sectors, building Avlight’s reputation for reliability and technical competence. The founders also embedded Total Quality Management (TQM) and value engineering (VA/VE) practices into company culture, ensuring that every product delivered optimum performance at competitive cost.
The turn of the century brought greater opportunities as multinational OEMs set up plants in India. To meet growing demand and adopt advanced manufacturing technologies, Avlight relocated to a purpose‑built facility at Industrial Model Township (IMT) Manesar in 2004. This plant, covering 25,000 square feet, housed injection‑moulding machines ranging from 80 to 700 tonnes and an automated assembly line. A modern tool‑room equipped with CAD/CAM design software and advanced machines allowed the company to design and fabricate injection moulds in‑house. By bringing tooling and production capabilities under one roof, Avlight reduced lead times and improved control over quality, enabling it to meet the stringent requirements of global OEMs.
The Manesar facility also marked the beginning of Avlight’s export activities. Within a year of moving, the company achieved TS 16949:2002 certification and began shipping products to customers in the United States, China, Canada and the United Kingdom. International business not only validated Avlight’s quality systems but also provided learning opportunities to refine processes and align with global best practices.
In 2014 Avlight established Avlight Auto Components (P) Ltd. at Noida, Uttar Pradesh, to manufacture wheel‑assembly components for Yamaha. This plant quickly ramped up production and, within five years, generated a turnover exceeding ₹240 crore in FY 2018‑19. The success of the Noida operation reinforced Avlight’s ability to set up dedicated plants for specific OEM projects and cemented its reputation as a preferred Tier‑1 supplier.
To serve clients in southern India and expand its footprint, Avlight commissioned a plant at Vallam Vadagal, Chennai in 2015. This facility mirrored the advanced capabilities of the Manesar plant, with electric injection‑moulding machines (60 to 700 tons) and auxiliary equipment such as hot‑runner controllers, dehumidifiers, auto‑loaders and ultrasonic welding machines. The plant also introduced automated metallising and coating lines for headlamp reflectors and lenses, further integrating the supply chain.
Recognising the importance of high‑precision tool design for complex lighting systems, Avlight formed a joint venture with Altrust Pro‑Tech Tooling PTE. Ltd., Singapore. The partnership leverages Altrust’s expertise in tool engineering and Avlight’s manufacturing strength to produce moulds and dies for automotive and industrial applications. This collaboration enhances Avlight’s capability to offer integrated solutions – from tooling and prototyping to mass production – giving it a competitive edge in global markets.
Avlight’s growth has been underpinned by sustained investment in product development and engineering. The company maintains a dedicated CAD/CAM and prototyping team that collaborates closely with customers during concept and design stages. Engineers perform value analysis/value engineering studies to optimise designs for cost and manufacturability. In‑house 3D printing and rapid prototyping shorten design cycles, allowing customers to see and test parts before final tooling.
Quality is central to Avlight’s ethos. The company’s quality policy emphasises providing reliable, cost‑effective and environment‑friendly products, focusing on customer satisfaction, productivity and minimising wastage, while continually upgrading processes and technology. To support this, Avlight runs a fully equipped quality laboratory featuring coordinate measuring machines (CMM), a photometry test lab, dust and water spray chambers, humidity chambers and plating‑thickness measurement equipment. These facilities enable comprehensive testing of optical performance, durability and environmental resistance, ensuring that products meet or exceed OEM specifications.
Behind every successful enterprise lies a committed team, and Avlight’s leadership has played a critical role in shaping its journey. Mr. Anil Anand, the Chairman and Managing Director, has over two decades of experience with leading Tier‑1 suppliers. He drives strategic planning, global relationships and operational excellence. Mr. Rajan Sharma, Director and Co‑founder, leads the tool and mould manufacturing division and brings more than 22 years of technical expertise. Together, their vision has fostered a culture where innovation, integrity and customer satisfaction thrive.
The Manesar facility also marked the beginning of Avlight’s export activities. Within a year of moving, the company achieved TS 16949:2002 certification and began shipping products to customers in the United States, China, Canada and the United Kingdom. International business not only validated Avlight’s quality systems but also provided learning opportunities to refine processes and align with global best practices.
Avlight’s long‑term success depends not only on financial growth but also on sustainability. The quality policy explicitly commits to delivering environment‑friendly products and minimising waste. The use of electric injection‑moulding machines reduces energy consumption, while recycling systems for plastics help lower material waste. Regular environmental audits ensure compliance with ISO 14001 standards, and the company works with customers to develop eco‑friendly designs, such as lightweight headlamp housings and energy‑efficient LED modules.
The emphasis on health and safety is reflected in OHSAS 18001 certification, which ensures that processes meet stringent occupational health and safety standards. Avlight’s factories have been designed with attention to ergonomic workstations, ventilation and hazard control, fostering a safe work environment and supporting employee well‑being.
From its early days, Avlight aspired to be a global player. After achieving TS 16949 certification and exporting to multiple countries in 2005, the company continued to expand its international customer base. Today Avlight supplies products to major OEMs and Tier‑1 suppliers in North America, Europe and China, in addition to serving a broad swathe of Indian manufacturers. This global presence is supported by sales and engineering teams that work closely with customers to understand regional regulations and design preferences.
Avlight’s ability to offer turnkey solutions – from concept design and tooling to production and assembly – sets it apart. Customers appreciate the flexibility and responsiveness of a partner that can adapt to changing demands, scale up quickly and deliver high‑precision components consistently. Over the last five years, the company has achieved an impressive compound annual growth rate (CAGR), a testament to its resilience and market relevance.
A chronological overview of Avlight’s journey reveals a series of milestones that showcase its steady ascent:
- 1996 – Foundation of Avlight in Faridabad; focus on automotive lighting equipment and plastic injection moulds.
- 2002 – Achieved TS 16949:2002 certification (quality management for automotive supply chains).
- 2004 – Moved to a new 25,000 sq ft facility in IMT Manesar; introduced injection‑moulding machines up to 700 tons and automated assembly.
- 2005 – Began exports to the United States, China, Canada and the United Kingdom.
- 2014 – Established Avlight Auto Components plant at Noida focused on Yamaha wheel assemblies.
- 2015 – Commissioned a new plant at Vallam Vadagal, Chennai.
- 2015 – Signed a joint venture with Altrust Pro‑Tech Tooling PTE. Ltd., Singapore.
- 2019 – Achieved group turnover of $50 million in FY 2018‑19.
These milestones are not just markers of growth but also indicators of Avlight’s ability to evolve with industry trends and customer expectations.
As the global automotive industry undergoes transformation – embracing electrification, autonomous driving, connected vehicles and sustainability – Avlight is positioning itself to remain a trusted partner. The company is investing in LED lighting technologies for two‑wheelers and passenger vehicles, smart assembly systems with vision inspection and digital manufacturing tools such as Industry 4.0 data analytics. Continued collaboration with global partners will bring new capabilities in tool design and material science.
Avlight also plans to expand its presence in consumer appliances and industrial lighting, sectors that demand precision moulded parts with high aesthetic quality. By leveraging its engineering base and strong supplier network, Avlight aims to offer comprehensive solutions that balance performance, cost and environmental responsibility. Further, the company is exploring opportunities to serve electric vehicle (EV) manufacturers, a space where lightweight, high‑efficiency lighting and component solutions are critical.
From a small workshop in Faridabad to a multi‑plant enterprise supplying customers on four continents, Avlight’s journey is a story of determination and innovation. The founders’ commitment to engineering excellence and customer satisfaction, supported by systematic investment in facilities, people and technology, has enabled Avlight to light the path for safer journeys around the world. With a foundation built on quality, sustainability and continuous improvement, Avlight is well positioned to continue its inspiring journey toward even greater heights.