A car plant making one million vehicles in a year sounds like a huge number. For Maruti Suzuki, that number has now become a reality at its Hansalpur facility in Gujarat. The company has started production at its fourth plant at the site, taking the facility’s annual production capacity to one million units.
This also gives Hansalpur an important position in Maruti Suzuki’s manufacturing network. It is now the company’s largest passenger vehicle manufacturing location in India by annual capacity.
Hansalpur Plant Capacity At A Glance
| Particular | Details |
|---|---|
| Location | Hansalpur, Gujarat |
| Total annual capacity | 1 million units |
| Number of plants | 4 |
| Total investment | ₹25,288.7 crore |
| Total area | 640 acres |
| Plant D capacity | 2.5 lakh units annually |
| First plant started | February 2017 |
| Current models | Baleno, Fronx, Swift, e Vitara |
The fourth plant, known as Plant D, adds another 2.5 lakh units of annual production. Before its start, the Hansalpur facility could produce 7.5 lakh vehicles every year.
Maruti Suzuki says this is the first manufacturing site in Suzuki’s global network to reach an annual capacity of one million vehicles. With this addition, the company’s total production capacity across India has increased to 29 lakh units per year.
e Vitara To Be Built At Plant D
The new plant will initially focus on Maruti Suzuki’s e Vitara electric SUV. Other models made at the Hansalpur facility include the Baleno, Fronx and Swift.
The facility is also an important export base for the company. Around 47 percent of Maruti Suzuki’s total overseas shipments in FY 2025 to 26 came from Hansalpur.
The manufacturing setup at the site is spread across four plants:
- Plant A makes the Baleno
- Plant B produces the Fronx and Swift
- Plant C makes the Fronx and e Vitara
- Plant D is dedicated to the e Vitara at present
A Big Manufacturing Investment
Maruti Suzuki has invested ₹25,288.7 crore in the Hansalpur facility so far. Around ₹3,900 crore of this amount has been allocated to Plant D.
The facility covers 640 acres and also has an integrated suppliers’ park. Production at Hansalpur started with Plant A in 2017. Plant B followed in 2019, while Plant C began operations in 2021.
The facility has also crossed several production milestones over the years:
- 1 million vehicles in October 2020
- 2 million vehicles in August 2022
- 3 million vehicles in December 2023
- 4 million vehicles in March 2025
- 5 million vehicles in May 2026
Railway Facility Helps Vehicle Dispatches
Hansalpur also has a dedicated railway siding for vehicle movement. Maruti Suzuki started operations at the facility in March 2024 under the Prime Minister’s GatiShakti programme.
More than 7.5 lakh vehicles have been dispatched through this system since March 2023. The company says this has helped reduce fuel use and CO2 emissions linked to vehicle transportation while also reducing pressure on roads.
In February 2026, the Gujarat railway siding was registered under Verra’s Verified Carbon Standard programme. Maruti Suzuki says it became the world’s first modal shift transportation project to receive this registration.
Focus On Skills And Local Development
The company’s work in Gujarat also extends beyond vehicle production. Maruti Suzuki has established Japan India Institutes for Manufacturing in Mehsana and Gandhinagar. More than 1,200 students have received training through these institutes.
The company is also working with the Gujarat government on advanced manufacturing labs at five ITIs. Automobile Skill Enhancement Centres have been established at three government ITIs, while EV and hybrid vehicle training is being offered at nine ITIs.
The International Automobile Centre of Excellence in Gandhinagar can train up to 5,000 students every year.
Education, Healthcare And Road Safety
Maruti Suzuki has also supported local communities around Hansalpur through several projects.
- A CBSE school in Sitapur has more than 800 students
- A multi specialty hospital has served over 1.5 lakh people from more than 400 villages
- Community projects cover 26 nearby villages
- More than 60,000 people have received driving training through AGIDTTR in Vadodara
The company says Hansalpur and the upcoming Sanand facility will play a major role in its long term plan to produce 4 million vehicles annually in India.