Maruti Suzuki Hansalpur Facility Reaches 1 Million Annual Capacity with Fourth Plant Launch

Maruti Suzuki India Limited has officially commenced commercial production at Plant D, the fourth manufacturing unit of its Hansalpur facility in Gujarat. Adding 250,000 units of annual capacity, this expansion elevates the facility’s total output from 750,000 to 1 million units per annum. This achievement marks a historic first for Suzuki globally, making Hansalpur the company’s first single manufacturing location to reach a 1-million-unit annual capacity, as well as India’s largest passenger vehicle manufacturing plant at a single site.

Investment, Production, and Export Footprint:
With the integration of Plant D which required an estimated investment of INR 39,000 million—Maruti Suzuki’s cumulative investment at Hansalpur has reached INR 252,887 million, bringing the company’s total national manufacturing capacity to 2.9 million units annually. Plant D will initially focus on manufacturing the company’s flagship Battery Electric Vehicle (BEV), the e VITARA. The broader Hansalpur complex currently produces the FRONX, Baleno, Swift, and e VITARA, functioning as a vital export engine that accounted for roughly 47% of the company’s total overseas shipments in FY 2025–26.

Leadership Insights on Long-Term Vision:
Mr. Hisashi Takeuchi, Managing Director & CEO of Maruti Suzuki India Limited, noted that Gujarat’s robust infrastructure and progressive industrial climate have turned the state into a premier manufacturing and export hub. He emphasized that the expanded capacity supports growing domestic and international demand while advancing the ‘Make in India, Make for the World’ vision. Together with the upcoming Sanand facility, these projects support the automaker’s long-term goal of producing 4 million units annually in India while contributing to Viksit Bharat through job creation and export growth.

Green Logistics and Sustainable Innovations:
Demonstrating a strong commitment to environmental sustainability, Maruti Suzuki commissioned India’s first automobile in-plant railway siding at Hansalpur in March 2024 under Prime Minister Narendra Modi’s GatiShakti initiative. Having dispatched over 750,000 vehicles via rail, the project has successfully curtailed fuel consumption, road congestion, and carbon emissions. In recognition of these efforts, the Gujarat in-plant railway siding became the world’s first modal shift transportation project registered under Verra’s Verified Carbon Standard (VCS) program in February 2026.

Corporate Social Responsibility and Community Development:
Alongside its industrial operations, Maruti Suzuki actively invests in community welfare across 26 villages neighbouring the manufacturing plant, focusing on water, sanitation, health, women and child care, tree plantations, and CCTV security infrastructure. To foster regional talent and upskill local youth, the company has established two Japan-India Institutes for Manufacturing (JIMs) in Mehsana and Gandhinagar, partnered with the Gujarat government to set up Advanced Manufacturing Labs (AMLs) across five ITIs, and helped build the International Automobile Centre of Excellence (iACE). Furthermore, the company established a modern CBSE English-medium school with Podar Education Network and a multi-specialty NABH-accredited hospital in partnership with the Zydus group in Sitapur, transforming regional education and healthcare access for over 1.5 lakh residents.