Maruti Suzuki India has upgraded its Hansalpur plant in Gujarat to the next level. The launch of Plant D for commercial production of vehicles has started from July 30, 2026. The plant has reached the capacity of producing 1million units annually. It became the first Suzuki manufacturing plant in the world to achieve that level.

The expansion has also helped establish Hansalpur as India’s largest manufacturer of passenger cars at one plant. Maruti Suzuki stated that the new plant will produce the e VITARA, which is its flagship BEV, as it further expands its BEV manufacturing capacity.

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Changes at Hansalpur

With the launch of Plant D, the annual production capacity at the plant has increased from 750,000 units to 1 million units. The cumulative investment at the plant currently stands at INR 252,887 million, with the latest plant costing about INR 39,000 million.

The Hansalpur complex covers an area of 640 acres and comprises an integrated supplier park. The present production includes Baleno, FRONX, Swift, and e VITARA models produced from its four plants.

Plant-wise Production Line-up

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

Mr. 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.”

A Crucial Export Base for Maruti Suzuki

The Hansalpur plant is also a vital exporting point for Maruti Suzuki. The company noted that the plant was responsible for about 47% of the total exports by the company during the fiscal year 2025-26. Thus highlighting the growing importance of Gujarat in the company’s global supply chain.

Maruti Suzuki has associated the development of the plant with its overall production strategy. Currently, the total annual production capacity of the company is 2.9 million units.

Logistics and Social Contribution Beyond Production

Maruti Suzuki emphasized how Hansalpur has turned out to be a role model for green logistics and social contribution.

Green logistics highlights

  • The first in-plant railway siding for automobiles in India was launched in Hansalpur in March 2024.
  • Over 750,000 vehicles have been transported using the siding since March 2023.
  • In February 2026, the siding got listed as the first modal shift transportation project under Verra’s Verified Carbon Standard.

ELCTRIK Speaks

The Hansalpur expansion of Maruti Suzuki is an important move not only for the company but also for the manufacturing sector of India. Through increasing its manufacturing facility, Maruti Suzuki proves its commitment not only to the industrial importance of Gujarat state as a manufacturing center but also in the EV market through the introduction of the e VITARA model. This represents a well-balanced combination of scaling, future-proofing and globalization through strategic investments in logistics, workforce and local communities.

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