That ship has sailed! However, in this case it is good news as the first load of Ford Ranger plug-in hybrid models is on the water to global destinations with the local company designated the sole producer of the eco-saver variant for world markets.This now opens up Australia and New Zealand as destinations, the antipodeans getting their ICE Rangers versions from Thailand.
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Ockert Berry, Vice President of Operations at Ford South Africa, described the launch as a monumental achievement for the plant. He emphasised the production of the Ranger PHEV at Silverton solidifies the facility’s central role in advancing Ford’s global sustainability goals.
“This plant is not merely producing vehicles—it is shaping the future of vehicle manufacturing,” Berry remarked.
As the exclusive production site for the Ranger PHEV, Silverton has undergone substantial upgrades to support the hybrid vehicle's advanced technology. The plant now boasts a flexible annual production capacity of 200 000 vehicles, with approximately 200 PHEV units rolling off the line daily in various configurations.
A new 1 376-square-meter battery assembly facility at the plant, featuring specialised hybrid conveyor systems and advanced testing processes, is capable of producing up to 62 000 battery packs annually. Innovations like vacuum leak testing with noise-cancelling technology ensure precision in the manufacturing process, while enhanced safety measures are in place with segregated high and low-voltage checks.
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The integration of the PHEV has also spurred significant modernization throughout the plant. Nearby chassis facilities in the Tshwane Automotive Special Economic Zone have introduced customised sub-assembly lines, while Silverton’s stamping and body shops have been equipped with new tools to accommodate the hybrid’s battery. Additionally, updates to the Trim, Chassis, and Final Assembly lines include dedicated high-voltage areas, ensuring the Ranger retains its 3 500 kg towing capacity while incorporating Pro Power Onboard features.
Ford South Africa has also intensified its sustainability efforts alongside these production upgrades. A new water recycling initiative at the Paint Shop now conserves 14 400 cubic meters of water annually, with plans to extend recycled water use throughout the entire plant. The revamped scrap yard now sorts and recycles materials like cardboard, plastic, and paper, aligning with Ford’s zero-waste-to-landfill goals.
The plant’s solar car park, which houses over 30 000 panels generating 13,4MW of energy, already powers daytime operations. Berry confirmed that plans are in place to further enhance renewable energy storage, with the long-term goal of achieving fully carbon-free manufacturing. Additionally, the Paint Shop has been upgraded with an advanced electro-dipping system designed to reduce energy consumption while improving finish quality.
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“Every Ranger, including the PHEV, reflects our environmental commitment,” Berry said. “Silverton is not just building vehicles—it is setting a new standard for sustainable manufacturing in the industry.”
With the Ranger PHEV set to launch globally in 2025, combining a 2,3-liter EcoBoost engine with a 75 kW electric motor, Ford’s South African facility is driving the brand toward a future of quieter, cleaner production, one hybrid at a time – with variants for South Africa still “undecided” at this time.
Colin Windell for Colin-on-Cars in association with
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