Maruti Suzuki Commissions 300kW Green Hydrogen Plant In Manesar, Haryana

Maruti Suzuki India has commissioned a 300 kW green hydrogen electrolyser at its Manesar manufacturing facility, in Haryana, as part of a pilot project aimed at reducing emissions from its production operations, the automaker announced on Thursday. The hydrogen generated at the plant will be blended with natural gas and used as process fuel in manufacturing. 

The project also lets the firm make greater use of solar power generated at Manesar, including electricity produced during holidays when manufacturing demand is lower.

Under the pilot programme, surplus solar energy is used to produce green hydrogen, which is then stored for use in the manufacturing process. 

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According to Maruti Suzuki, the experience gained from the project will be used to assess the potential for expanding green hydrogen adoption across its manufacturing facilities in Haryana and Gujarat.

The initiative is part of Maruti Suzuki's bigger effort to diversify the renewable energy sources used in its manufacturing operations. It also reflects the company's adoption of the resource-efficiency philosophy of its parent, Suzuki Motor Corporation, known as "Sho-Sho-Kei-Tan-Bi," which focuses on making things smaller, fewer, lighter, shorter and more efficient.

“Just like we have adopted a multi-pathway approach for products, we have also embarked on a journey of multiple renewable energy solutions for manufacturing operations. The commissioning of our 300 kW Green Hydrogen plant is aligned with the Government of India’s Green Hydrogen Mission. This, along with expansion of solar, biogas and installation of battery energy storage system reflects our commitment to transition to cleaner and sustainable energy solutions," Hisashi Takeuchi, Managing Director & CEO, Maruti Suzuki India Limited, said in a statement.

According to India's biggest automaker, manufacturing emissions are an increasingly important consideration for India's industrial competitiveness, alongside conventional factors such as cost and product quality.

“India is emerging as a manufacturing powerhouse, and its competitive position may not depend solely on cost and quality, but also on CO2 intensity. With such initiatives, we are building capability today so that we can support a low-carbon and more energy-efficient manufacturing ecosystem tomorrow. Through multiple clean technologies, we aspire to reduce our carbon footprint in manufacturing operations from the present 615,000 tonnes to 266,000 tonnes in FY 2030-31i,” Takeuchi added.

Green hydrogen is being added to a broader portfolio of measures that Maruti Suzuki is using to reduce emissions from its manufacturing facilities. These include captive solar power generation, renewable electricity sourced through government channels and power purchase agreements with third-party suppliers for solar and wind energy.

The company is also developing other options for replacing conventional process fuels. A 10-tonnes-per-day biogas plant at its Kharkhoda facility is in an advanced stage of development and is scheduled for commissioning within FY 2026-27.

The automaker has already commissioned a 1 MWh battery energy storage system at Kharkhoda. The system adds storage capacity to its renewable energy ecosystem and could help improve the utilisation of intermittent renewable power within manufacturing operations.

Compressed biogas (CBG) is another part of the company's process-fuel strategy. Maruti Suzuki said its board has approved four CBG projects, with an investment allocation of ₹5,610 million.

In another development, Suzuki Motor Corporation, in partnership with organisations including the National Dairy Development Board and dairy industry unions, is mulling to establish 10 biogas plants across India. 

Three of these facilities are already operational in Gujarat.

The pilot's performance and operating economics will determine the scope for wider deployment. If scaled, green hydrogen could add another pathway for reducing the carbon intensity of process energy as the company expands its renewable power, biogas and energy-storage capabilities across its manufacturing footprint.