Maruti Suzuki Plant D Starts Production At Hansalpur Gujarat Facility

Maruti Suzuki Plant D Begins Commercial Production At Hansalpur Facility

Maruti Suzuki India Limited has commenced commercial production at the fourth plant, designated Plant D, of its Hansalpur manufacturing facility in Gujarat, according to a regulatory filing dated July 30, 2026. Maruti Suzuki Plant D adds an annual production capacity of 250,000 units, increasing the total capacity at the Hansalpur location from 750,000 units to 1 million units per annum. The new facility will initially support production of the company’s flagship battery electric vehicle model, the e VITARA.

With the commissioning of Plant D, the overall annual production capacity of Maruti Suzuki India Limited across its domestic manufacturing facilities has reached 2.9 million units. The expanded capacity includes 1 million units at Hansalpur, 900,000 units at Manesar, and 500,000 units each at Gurugram and Kharkhoda facilities. The production expansion strengthens the company’s manufacturing footprint in India while preparing for increasing demand across conventional and electric vehicle segments.

Investment And Electric Vehicle Manufacturing Expansion

The new Plant D represents an estimated investment of Rs 3,900 crore, taking the cumulative capital expenditure at the 640-acre Hansalpur site to Rs 25,288.7 crore. The facility will operate as an important production base for Maruti Suzuki’s electric mobility strategy, beginning with the assembly of the e VITARA battery electric vehicle. The investment highlights the company’s focus on scaling manufacturing capability and supporting future vehicle electrification requirements.

The Hansalpur manufacturing complex currently produces multiple models, including the FRONX, Baleno, and Swift. During FY 2025-26, the facility contributed approximately 47% of Maruti Suzuki’s total export volume. The addition of Plant D further increases the strategic importance of the Gujarat facility by combining export capability, high-volume production, and electric vehicle manufacturing readiness.

Hansalpur Facility Development Timeline

The Hansalpur complex was developed through multiple production phases, beginning with Plant A in February 2017. Plant B became operational in January 2019, followed by Plant C in April 2021. The commissioning of Plant D completes the fourth manufacturing phase at the site and enables the facility to achieve a total production capacity of 1 million units annually.

Hansalpur Plants And Production Capacity Expansion

The commissioning of Plant D marks a significant milestone in Maruti Suzuki India Limited’s manufacturing expansion strategy. The additional capacity will support production flexibility, strengthen domestic and export operations, and provide dedicated capability for electric vehicle assembly. The Hansalpur facility is expected to play a larger role as automotive manufacturers continue adapting to changing market requirements and increasing electrification trends.

Frequently Asked Questions

What is the production capacity added by Maruti Suzuki Plant D?
Maruti Suzuki Plant D adds 250,000 units of annual production capacity at the Hansalpur facility in Gujarat. The new plant increases Hansalpur’s total capacity to 1 million units annually and supports assembly of the e VITARA electric vehicle. The facility represents continued investment in manufacturing expansion, electric mobility preparation, and export-oriented production capabilities while strengthening the company’s overall domestic production network.