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

Maruti Suzuki India has started commercial production at the fourth manufacturing line at its Hansalpur facility in Gujarat, raising the company's total annual production capacity to 2.9 million vehicles and making the plant the first Suzuki manufacturing site globally to reach an annual capacity of 1 million units. 

Hansalpur's 4th Line: Investment, Capacity and the e VITARA

The new line adds 250,000 units of annual capacity, taking Hansalpur's production capability from 750,000 units to 1 million units a year. The milestone makes the Gujarat facility as India's largest passenger vehicle manufacturing complex at a single location. 

Maruti Suzuki said it has invested an estimated Rs 3,900 crore in the fourth plant, taking the cumulative investment at Hansalpur to about Rs 25,288.7 crore. The new production line will initially manufacture the all-electric e VITARA sport utility vehicle. 

The 640-acre Hansalpur facility currently manufactures the FRONX, Baleno, Swift and e VITARA. It has also become a key export base for the automaker, accounting for nearly 47% of Maruti Suzuki's overseas shipments in the 2025-26 financial year.

Why Gujarat Matters: Maruti's Export and Expansion Roadmap

"Gujarat has emerged as a manufacturing and export hub for Maruti Suzuki, backed by strong infrastructure and a progressive industrial ecosystem," Managing Director and Chief Executive Hisashi Takeuchi said.

"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. 

Takeuchi said the Hansalpur facility, together with the upcoming greenfield plant in Gujarat, would play a key role in helping the company achieve its long-term goal of reaching 4 million units of annual production capacity in India by the end of the decade. The company is also expanding capacity at its Kharkhoda manufacturing facility in phases.

Rail Logistics and FY26 Production Numbers

The Gujarat plant also houses India's first automobile in-plant railway siding, commissioned under the Prime Minister's GatiShakti programme. Maruti Suzuki said it has dispatched more than 750,000 vehicles through rail from the facility since operations began, helping reduce carbon emissions, fuel consumption and road congestion. The railway siding also became the world's first modal shift transportation project to be registered under Verra's Verified Carbon Standard programme earlier this year. 

In the 2025-26 financial year, Maruti Suzuki manufactured 2.31 million vehicles, including 1.18 million passenger cars and 971,594 utility vehicles. It sold 1.82 million vehicles in the domestic market and exported 443,825 units during the year.