Ford South Africa has begun full-scale production of the first-ever Ford Ranger plug-in hybrid electric vehicle (PHEV) at its Silverton manufacturing plant.
The Ranger PHEV, exclusively produced in South Africa for global export, is a key component of Ford’s global sustainability strategy. This is supported by the Silverton plant’s efforts to adopt more environmentally friendly and sustainable manufacturing processes.
“The addition of the high-tech new Ranger PHEV to our production portfolio is an important milestone in Ford’s manufacturing history in South Africa,” says Ockert Berry, vice president of operations for Ford South Africa. “This makes the Silverton manufacturing plant central to Ford’s Ranger sustainability efforts, as we are the global source for both the new plug-in hybrid and the established Ranger line-up exported to over 100 markets.”
Ford’s Silverton manufacturing plant has been designated the global production hub for the Ranger Plug-in Hybrid (PHEV), a testament to the facility’s significant upgrades and enhanced adaptability. Producing the PHEV alongside the Ranger expands its global reach, with key upgrades and highlights including:
• Silverton’s capacity is 200 000 vehicles annually (720/day) including approximately 200 Ranger PHEVs across various specifications and both left- and right-hand drive.
• Europe is the primary export region for the Ranger including the PHEV from 2025, building on its 10-year reign as the best-selling pickup. Ranger PHEV marks Ford’s first Ranger exports to Australia and New Zealand from Silverton.
• A new PHEV battery assembly plant featuring a 1376 m2 assembly line and a 2116 m2 logistics warehouse enables 62 000 annual battery pack production, integrating advanced handling, testing and Ford-first innovations, including a hybrid conveyor system for improved ergonomics and quality.
• Pioneering battery pack testing using vacuum testing with differential noise cancellation eliminates environmental interference. This facility is among the first to separate low voltage, vacuum leak and high voltage testing for enhanced production quality and safety.
• Ford South Africa’s 10 320 m2 stamping plant introduced new dies for the PHEV charging port, while the 44 000 m2 body shop gained a new load box floor line to accommodate the battery pack, raising the load floor by only 31mm.
• The trim, chassis and final assembly (TCF) line was modified to integrate PHEV components, including a new battery sub-assembly line. Dedicated areas ensure that high-voltage work meets safety standards.
Launching in Europe, Australia and New Zealand in 2025, the South African-made Ranger PHEV combines a 2.3L EcoBoost engine with a 75 kW electric motor and a 11,8 kWh battery. It maintains the Ranger’s 3500 kg towing capacity and introduces Pro Power Onboard.
Environmental efforts
Along with the extensive Silverton manufacturing plant upgrades to support the Ranger PHEV global production, significant changes are being implemented throughout the facility, reinforcing Ford South Africa’s commitment to sustainability.
“We have implemented an extensive range of waste reduction and recycling initiatives, including a new water recycling project in the paint shop that conserves around 14,400m3 of water annually, and we have plans to expand recycled water usage across the plant,” Berry says.
A new scrap yard has been constructed that increases the amount of cardboard, paper and plastic waste that is sorted on site and recycled in line with Ford’s objective of reaching zero waste to landfill across its worldwide operations. The Silverton plant team continues to investigate alternatives for its waste, possibly turning it into a sustainable by-products that can benefit both the environment and future business opportunities.
All such initiatives are complemented by the Silverton manufacturing plant’s pioneering solar carpark, which uses more than 30 000 solar panels to generate 13,4 MW of electricity – sufficient to power the entire plant during the day.
“We are very close to bolstering our solar system with other alternative energy and storage supplies that will take us a big step closer to exclusively using carbon-free electricity for all of our manufacturing operations,” Berry says.
The Silverton plant’s paint shop is also undergoing extensive upgrades that will further improve the paint application processes and quality, while achieving greater energy efficiency. The installation of a sophisticated new pre-treatment electro-dipping system is underway as a critical step in modernising the facility, contributing to improved paint quality and durability. Phased installations are planned to ensure minimal disruption to current production volumes.
“This truly is a Built Ford Proud moment as every Ford Ranger we produce, including the advanced new Ranger PHEV, benefits from these wide-ranging environmental upgrades and improvements,” Berry says. “It positions the Silverton plant as a leader in creating a more environmentally conscious and sustainable manufacturing ecosystem.”
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