South Africa’s Silverton Manufacturing Plant has kicked off full-scale production of Ford’s new Ranger Plug-in Hybrid Electric Vehicle (PHEV), marking a pivotal shift in the company’s global sustainability strategy. The hybrid pickup, assembled exclusively in South Africa for international markets, underscores Ford’s commitment to greener manufacturing and innovation.
Ockert Berry, Ford South Africa’s Vice President of Operations, hailed the milestone as transformative: “Producing the Ranger PHEV here cements Silverton’s role as a cornerstone of Ford’s global manufacturing network. This facility isn’t just building vehicles—it’s shaping the future of sustainable mobility.”
However, the Ranger PHEV is currently not earmarked for local introduction but is “under consideration”.
Sole production hub
Designated as Ford’s sole global production hub for the Ranger PHEV, the Silverton plant has undergone extensive upgrades to handle the hybrid’s advanced technology. With an annual capacity of 200,000 vehicles, including 200 daily PHEV units across left and right-hand drive configurations, the facility now supports exports to Europe, Australia, and New Zealand from 2025.
Key enhancements include a dedicated 1 376-square-metre PHEV Battery Assembly Plant, equipped to produce 62,000 battery packs yearly. Innovative testing methods, such as vacuum leak detection with noise-cancelling tech, ensure safety and precision. Meanwhile, hybrid conveyor systems blend automation and manual processes to streamline assembly without compromising ergonomics.
Environmental upgrades
Ford South Africa has paired its hybrid rollout with sweeping environmental upgrades. A sprawling solar car park, boasting over 30,000 panels, generates 13.4MW of daytime energy - enough to power the entire plant.
Water-saving initiatives, including a Paint Shop recycling project, save 14,400 cubic metres of water annually, while a new scrap yard maximises waste sorting to edge closer to zero landfill targets.
Further modernisation is underway in the Paint Shop, where a cutting-edge electro-dipping system promises enhanced efficiency and durability. “Every Ranger leaving Silverton, hybrid or not, benefits from these eco-upgrades,” Berry emphasised. “We’re not just making vehicles - we’re building a sustainable blueprint for global manufacturing.”
EcoBoost engine
Combining a 2.3-litre EcoBoost engine with a 75kW electric motor and 11,8kWh battery, the Ranger PHEV retains its diesel counterpart’s 3 500kg towing prowess while introducing Pro Power Onboard for auxiliary energy. Despite the hybrid’s added tech, Ford engineers have limited the load floor height increase to just 31mm.
As the Silverton plant gears up to bolster solar capacity with additional renewable energy storage, Berry remains bullish about South Africa’s role in Ford’s global ambitions: “We’re proving that world-class, sustainable manufacturing isn’t confined to traditional hubs. When you see the quality and innovation coming out of Silverton, it’s clear we’re leading the charge.”