The present study aimed to identify significant injury risk factors in an aluminum smelting plant by examining both local workplace hazards, individual, and organizational factors. The study included 120 injured workers and 480 non-injured workers from an aluminum smelter in eastern India. Data on personnel factors, exposure to hazards, and organizational factors were collected. Chi-square tests and logistic regression were used for statistical analysis. Bivariate analysis revealed statistically significant associations between injury occurrence and all types of hazard exposures and organizational factors (p < 0.01), except personal factors such as age and education. In the multivariate analysis, among the various hazard exposures, machinery-related hazards demonstrated the highest adjusted odds ratio (adOR = 3.08), followed by hand tools-related hazards (adOR = 1.94) and manual handling hazards (adOR = 1.88). Workers aged 25–45 years had a significantly lower risk of injury than younger workers (adOR = 0.49). Among organizational factors, poor working conditions (adOR = 3.16) and an unsafe safety environment (adOR = 2.62) were found to be significantly associated with increased injury risk. Results suggest that safety interventions should be focused on targeted engineering controls addressing high-risk machine and hand tool hazards, and systemic improvements to working conditions and safety environment.