Solar project powering Gauteng facility for world’s leading wheel manufacturer is now live.
Maxion Wheels, one of the world’s leading producers and suppliers of wheels for passenger and commercial vehicles, and Terra Firma, a leading commercial and industrial solar and storage solutions provider in South Africa, have announced that a 2.9 MWp solar project installed at Maxion’s manufacturing plant in Johannesburg is now live and powering the plant. The energisation was celebrated at Maxion Wheels South Africa’s recent 60th anniversary event.
The carport and ground mount solar installation will supply approximately 20% of the facility’s annual energy needs, reducing Maxion’s reliance on the national grid and providing protection against energy-related tariff increases. It will also reduce greenhouse gas (GHG) emissions by approximately 5 100 tons per year. A second phase of additional rooftop solar capacity is scheduled for completion in Q1 2026, with the possibility of integrating a Battery Energy Storage System (BESS) for energy arbitrage and backup power.
The panels cover a total area of 13 250m², which is made up of an unused open area of 1 250m², another ground mount open area of 9 500m² (2 000kWp) and the roof structures of the carpark account for 2 500m² (475kWp).
The installation side of the project took 7 months to complete, starting in March 2025 and ending in September 2025.
The 1.6 MWp Phase 2 of the project will be installed on the rooftop of the manufacturing facility.
Maxion Wheels have installed a 2.9 MWp solar project to power the manufacturing plant. The panels cover a total area of 13 250m², which is made up of an unused open area of 1 250m², another ground mount open area of 9 500m² (2 000kWp) and the roof structures of the carpark account for 2 500m² (475kWp). The 1.6MWp Phase 2 of the project will be installed on the rooftop of the manufacturing facility
It is worth noting that the solar power project installed at the Maxion Wheels, Gauteng facility is now the largest in the Maxion Wheels Group network. The following Maxion Wheels sites are also solar powered: Saraburi – Thailand, Pune – India (three plants), Ostrava – Czech Republic (CZA aluminium plant), Manisa – Turkey (JAWS plant), Chihuahua – Mexico and San Luis Potosi – Mexico.
Boosting automotive industry competitiveness and sustainability
South Africa’s automotive industry contributes 5.3% of GDP and supports over 500 000 jobs across the value chain. However, the sector is under increasing pressure due to global trade barriers, growing competition and decarbonisation requirements.
For manufacturers such as Maxion Wheels, where electricity is one of the largest input costs due to energy-intensive processes, managing energy spend is critical to maintaining competitiveness. Solar power offers an accessible solution that enables manufacturers to reduce and manage costs, improve resilience and reduce climate impact.
Focus on engineering precision
As one of the world’s leading manufacturers of steel and aluminium wheels, Maxion Wheels produces approximately 50 million wheels per year across its 31 locations on five continents. The Johannesburg plant produces high-precision aluminium wheels for major automotive OEM customers in South Africa.
Maxion Wheels South Africa’s business is all about manufacturing and supplying OEMs with aluminium wheels – some more complicated than others
Given the plant’s intensive industrial processes, continuous uptime is mission-critical for Maxion. The plant relies on extensive machinery including various robots, integrated foundry systems and automated conveyor networks operating around the clock.
For Terra Firma, this meant ensuring continuous power supply while meeting strict health, safety and operational standards at every step of the solar project deployment process.
Under a comprehensive multi-year Power Purchase Agreement (PPA), Terra Firma developed, designed, engineered and installed the project, and will manage and maintain it for its lifetime. The PPA delivery model offers the cost and GHG emission reduction benefits of solar power, without the capital expenditures or risks of ownership.
Initial melting of ingot and scrap metal before degassing is done on two Striko tower furnaces before the metal is transferred to the individual low-pressure die-casting machines
“The 60th anniversary of Maxion Wheels South Africa is an opportunity to celebrate our legacy of manufacturing excellence while looking ahead to how we can continue strengthening our leadership and resilience for decades to come. Integrating renewable energy into our operations marks a significant milestone in our Roadmap Zero strategy towards net-zero emissions by 2040, and reinforces our position as a global leader in advanced manufacturing,” said Milos Despotovic, Managing Director, Maxion Wheels South Africa.
“We thank Maxion Wheels for entrusting Terra Firma as their energy partner to bring this project to life. Together, we’re demonstrating how solar power helps enable long-term sustainability, resilience and global competitiveness for South Africa’s automotive manufacturing sector,” said Grant Berndsen, CEO, Terra Firma.
For further details visit www.maxionwheels.com
