Maruti Suzuki Starts Production at Hansalpur Facility’s 4th Line, Total Capacity Now at 2.9 Million Units

Maruti Suzuki India Limited has commenced commercial production at the fourth plant, designated Plant D, of its manufacturing facility in Hansalpur, Gujarat, according to a regulatory filing on July 30, 2026. The addition of the new plant, which has an annual production capacity of 250,000 units, increases the total manufacturing capacity at the Hansalpur location from 750,000 units to 1 million units per annum.

With the commissioning of Plant D, the automaker's overall annual production capacity across all domestic facilities reaches 2.9 million units. The total capacity includes 1 million units at Hansalpur, 900,000 units at Manesar, and 500,000 units at Gurugram and Kharkhoda each.

The new plant represents an estimated investment of Rs 3,900 crore, bringing cumulative capital expenditure at the 640-acre Hansalpur site to Rs 25,288.7 crore. Plant D will initially serve as the assembly line for the company's flagship battery electric vehicle model, the e VITARA.

The Hansalpur facility, which also produces the FRONX, Baleno, and Swift models, accounted for approximately 47% of Maruti Suzuki's total export volume in FY 2025-26. Commercial operations at the Hansalpur complex originally began with Plant A in February 2017, followed by Plant B in January 2019 and Plant C in April 2021.