Maruti Suzuki Starts Production at Fourth Hansalpur Plant, Capacity Reaches 1 Million Units

Hansalpur: Maruti Suzuki India Limited today commenced commercial production at the fourth plant (Plant D) of its Hansalpur facility in Gujarat. The fourth plant, with an annual production capacity of 250,000 units, has increased the Hansalpur facility’s total annual production capacity from 750,000 units to 1 million units, the company announced.

According to the company, this marks the first time in Suzuki’s history that the total annual production capacity at a single manufacturing facility has reached 1 million units. It also makes Maruti Suzuki’s Hansalpur facility India’s largest passenger vehicle manufacturing facility at a single location.

The company, in a regulatory filing, said that with the commissioning of Hansalpur Plant D, Maruti Suzuki’s total manufacturing capacity has increased to 2.9 million units per annum. The cumulative investment at the Hansalpur facility stands at INR 252,887 million (Rs 25,288.7 crore). This includes an estimated investment of INR 39,000 million (Rs 3,900 crore) for Plant D. The new plant will initially produce the company’s flagship battery electric vehicle (BEV), the e VITARA.

The Hansalpur facility produces the FRONX, Baleno, Swift and e VITARA. The facility has emerged as a major export hub for the company, accounting for nearly 47% of its overall overseas shipments in FY 2025-26.

Speaking on the expansion, Hisashi Takeuchi, Managing Director & CEO, Maruti Suzuki India Limited, said, “Gujarat has emerged as a manufacturing and export hub for Maruti Suzuki, backed by strong infrastructure and a progressive industrial ecosystem. The start of commercial production at the fourth plant of our Hansalpur facility augments its annual production capacity to one million vehicles, making it India’s largest passenger vehicle manufacturing facility at a single location. The new line will further strengthen our ability to meet the growing demand from customers in India and overseas while advancing our ‘Make in India, Make for the World’ vision and expanding our global footprint.”

He added, “Together, the Hansalpur and the upcoming Sanand facility in Gujarat will play a pivotal role in achieving our long-term ambition of producing 4 million units annually in India. These projects reflect our commitment to strengthening India’s manufacturing competitiveness, creating employment, boosting exports and contributing towards Viksit Bharat.”

Maruti Suzuki manufacturing footprint

• Hansalpur: 1 million units per annum
• Manesar: 0.9 million units per annum
• Gurugram: 0.5 million units per annum
• Kharkhoda: 0.5 million units per annum

Overview of Maruti Suzuki’s Hansalpur facility in Gujarat

• Location: Hansalpur, Gujarat
• Area: 640 acres with an integrated suppliers’ park
• Total investment: INR 252,887 million (Rs 25,288.7 crore)
• Production capacity: 1 million units annually

Start of operations

• Plant A – February 2017
• Plant B – January 2019
• Plant C – April 2021
• Plant D – July 2026

Current production models

• Plant A: Baleno
• Plant B: FRONX & Swift
• Plant C: FRONX & e VITARA
• Plant D: e VITARA

Production milestones

• Cumulative 1 million – October 21, 2020
• Cumulative 2 million – August 18, 2022
• Cumulative 3 million – December 4, 2023
• Cumulative 4 million – March 4, 2025
• Cumulative 5 million – May 7, 2026