Maruti Suzuki's Railway Initiative Transforms Vehicle Dispatch, Cuts Emissions
In a significant stride toward sustainable logistics, Maruti Suzuki India Limited has successfully dispatched one lakh cars from its Manesar plant in Gurgaon using an in-plant railway siding over the past nine months. This innovative approach has not only streamlined operations but also contributed to a substantial reduction in environmental impact, with estimated savings of 16,800 metric tonnes of carbon dioxide (CO2) emissions.
From Trucks to Trains: A Logistics Revolution
Previously, vehicles manufactured at the Manesar facility were transported across the country exclusively via trucks. However, since June 2025, when the railway track became operational at the plant, Maruti Suzuki has shifted to rail-based dispatch. A railway siding, defined as a short auxiliary track connected to a main line for freight handling, has enabled this transition, marking a pivotal change in the company's outbound logistics strategy.
Hisashi Takeuchi, Managing Director & CEO of Maruti Suzuki India Limited, emphasized the dual benefits of this initiative. "This initiative reinforces our commitment to reduce our carbon footprint in vehicle dispatches while easing overall road congestion," he stated. "At full capacity, the Manesar siding has the capability to dispatch 450,000 units annually."
Infrastructure and Scale of the Manesar Railway Siding
Spanning 46 acres within the Maruti Suzuki Manesar facility, the railway siding is a state-of-the-art infrastructure project. It features:
- A fully electrified corridor with four full-length tracks for rakes and one track for engine escape.
- A two-floor station building and a dedicated pathway for guards and drivers along the tracks.
- Advanced electronic train interlocking systems for enhanced safety and efficiency.
Registered under the PM GatiShakti National Master Plan, this siding is part of the 126 km Haryana Orbital Rail Corridor (HORC), which runs from Sonipat to Palwal in Haryana. It stands as India's largest automobile in-plant railway facility and is the second PM GatiShakti in-plant terminal for the auto industry, following the Gujarat railway siding.
Operational Impact and Model Diversity
Since its commencement, the siding has facilitated the dispatch of over 500 rakes, carrying popular Maruti Suzuki models such as Alto, WagonR, Brezza, Dzire, Ertiga, Celerio, XL6, Eeco, and Super Carry. These vehicles are manufactured at both the Gurgaon and Manesar facilities. Through a dedicated hub-and-spoke model, the company now services 380 cities from 17 hubs, significantly expanding its logistical reach.
Investment and Future Goals
The project was executed by Haryana Orbital Rail Corporation Ltd (HORCL), a joint venture. Maruti Suzuki has committed Rs 325 crore toward developing the HORC and invested an additional Rs 127 crore in internal yard development, bringing the total investment to approximately Rs 452 crore.
Takeuchi highlighted the company's progress in rail-based logistics, noting that in CY 2025, Maruti Suzuki set a record by dispatching over 5.85 lakh vehicles via railways. "In the past decade, our share of rail mode in outbound logistics has grown exponentially, from 5% in 2016 to 26% in 2025," he explained. "Going forward, we aim to scale up rail-based vehicle dispatches from the current 26% to 35% by FY 2030-31, in line with our commitment to build efficient and sustainable logistics and contribute to India's net-zero ambition."
This initiative underscores Maruti Suzuki's dedication to environmental stewardship and operational efficiency, setting a benchmark for the automotive industry in sustainable transportation practices.
