The geometric design of highway primarily depends on the design speed, super elevation, sight distance, gradient, and curves. In the recent decade, India has shown a tremendous increase in rate of population growth. It takes a toll on the existing transportation infrastructure. Economic parameters are of paramount importance for the viability of any project. For enhancing the utility of current transportation infrastructure, a lot of Government’s expenditure is incurred which is not feasible in the long run. This paper involves deciding a feasible alignment option of an expressway to provide better connectivity between two major cities in Maharashtra and to promote industrial development in the region. The aim of an industrial corridor is to promote industrial development, attract investment, and facilitate the growth of manufacturing industries. The existing route experiences mixed traffic conditions, and during peak hours, the journey may take a bit longer as opposed to the non-peak hours. A continuous ribbon development is observed along the entire stretch of the existing National Highway, further complicating efforts to expand the road. Therefore, it is best suited to evaluate a greenfield alignment option. The paper involves identifying the best suited alignment option. The selection process prioritizes factors encompassing engineering feasibility, social and environmental impacts, and road safety considerations. It will also focus on maximizing industrial connectivity. The chosen alignment option will be assessed in accordance with the guidelines laid by IRC: SP 19–2020.