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In The Spotlight

Daystar Power Group expands solar installations across Nestlé facilities in Côte d’Ivoire, Ghana and Senegal

Energy

Daystar Power Group has strengthened its energy partnership with Nestlé across West Africa, with solar installations now fully operational at four manufacturing facilities in Côte d’Ivoire, Ghana and Senegal

The projects bring Nestlé’s total installed solar capacity across these sites to 6,884 kWp, close to 7 MW, making it one of the region’s largest commercial and industrial solar partnerships.

The four facilities, including two sites in Abidjan, one in Tema and one in Dakar, are now operational. Each solar system has been customised to match the specific grid conditions and operational requirements of its respective location.

“Nearly 7 megawatts across four Nestlé facilities is a number we are proud of, but what it represents matters more than the figure itself. It means that one of the world's most demanding manufacturers has tested our model, trusted it, and come back. Our job now is to keep earning that, across every market where industry needs energy it can count on,” added Yischai Beinisch, CEO, Daystar Power Group.

From one site to four sites

The collaboration began with a single installation before expanding across three countries and four manufacturing facilities. In Côte d’Ivoire, Daystar Power has delivered 3,447 kWp of solar capacity across two Abidjan sites. Ghana’s Tema factory now operates with a 2,547 kWp system, while Senegal’s Dakar facility has an 890 kWp installation.

Each project has been designed to deliver measurable environmental and social benefits, including lower greenhouse gas emissions and improved energy resilience. The systems are tailored to local grid conditions and operational demands, providing reliable clean energy access while supporting local development and contributing to Nestlé’s publicly stated net-zero commitments.

“This investment reflects our commitment to building a business that not only grows but does so responsibly. By advancing solar energy projects in Ghana, Côte d'Ivoire, and Senegal, we are embedding sustainability into our growth, reinforcing our role as a force for good, creating long-term value for communities, and ensuring that our footprint actively contributes to a cleaner, more resilient future,” stated Samer Chedid, CEO, Nestlé Central and West Africa Region.

A footprint that keeps growing

Nestlé’s manufacturing network continues to expand across West Africa, including markets where Daystar Power has established strong operational capabilities. With projects now spanning three countries and nearly 7 MW of installed solar capacity, the partnership has created a foundation to support future clean energy expansion.

 
 

BCM Group wins US$400m Tulu Kapi contract, supporting Ethiopia’s major gold project with comprehensive mining services

Mining

BCM Group has been awarded the flagship mining services contract for the Tulu Kapi Gold Project in Ethiopia, reinforcing its position as one of Africa’s leading mining contractors

The long-term agreement, valued at more than US$400mn over the project’s initial nine-year mine life, was awarded by KEFI Gold and Copper through its Ethiopian subsidiary, Tulu Kapi Gold Mines Share Company (TKGM).

Under the agreement, BCM will deliver a comprehensive suite of mining services, including the supply, operation and maintenance of the mining fleet, recruitment, training and management of local employees, and execution of full-scale mining operations under TKGM’s supervision. The contract also includes the procurement and deployment of a new Caterpillar mining fleet to support project development and future production targets.

BCM group CEO Paul Coe said, “We are delighted to have been selected as the mining services contractor for the Tulu Kapi Gold Project. This award reflects BCM’s proven track record of successfully developing and operating mines across Africa and the Middle East, often in emerging jurisdictions where strong partnerships, local workforce development and operational excellence are critical to success.

“Tulu Kapi is a landmark project for Ethiopia’s mining industry, and we look forward to working closely with KEFI, TKGM, the Ethiopian Government and local communities to help deliver a safe, efficient and sustainable mining operation.”

With over 30 years of experience in delivering mining projects across Africa and the Middle East, BCM brings extensive expertise in mine development, fleet management and contract mining services. The Tulu Kapi project marks BCM’s entry into East Africa and highlights its ability to support major mining developments across the continent.

Tulu Kapi contains probable ore reserves of approximately 1.05 million ounces of gold and total mineral resources of 1.72 million ounces. Developed in partnership with the Ethiopian Government, the project is expected to contribute significantly to Ethiopia’s export earnings, job creation and economic growth.

The contract award further strengthens BCM’s reputation as a trusted partner for large-scale mining projects and reflects its ongoing commitment to its mission of Bringing Mines to Life across Africa and beyond.

Advanced LNG Vessel makes Suez Canal debut. (Image source: Suez Canal Authority)

Logistics

The Suez Canal Authority (SCA) has announced the successful transit of the CMA CGM NOTRE DAME, a giant French container ship and one of the world’s largest LNG-powered vessels, during its maiden passage through the Canal

The vessel travelled as part of the southern convoy while operating a route from Singapore to France.

Owned by French shipping company CMA CGM, the vessel measures 399.9 metres in length, has a 61.3-metre beam, a 16.5-metre draft, weighs 245,000 tonnes, and can accommodate 24,212 TEUs.

Powered by LNG and equipped with advanced AI technology, CMA CGM NOTRE DAME is considered France’s most technologically advanced vessel. The ship is designed for long-distance voyages and operates under the FAL3 maritime service connecting the Far East and North-West Europe.

SCA Chairman and Managing Director Adm. Ossama Rabiee directed teams to ensure the vessel’s safe passage through the deployment of senior pilots and escort tugboats. Following SCA protocol, senior pilots welcomed the crew and presented a commemorative gift to the shipmaster.

Adm. Rabiee highlighted the Canal’s readiness to handle the world’s largest container vessels, citing its strategic importance in protecting global supply chains and delivering economic efficiencies. He added that the SCA continues to enhance maritime services and introduce new navigation solutions to meet client requirements and maintain the highest safety standards for mega vessels.

African Review

  • In the final webinar of its African Review-hosted 2023 campaign, Convergent Group explored its modern, eco-friendly concrete solutions for African projects

    Such solutions – delivered to cut maintenance costs by eliminating hazardous silicate products – were showcased by company experts in the form of Jean-Claude Biard, SEO of Convergent Group SA; Mputu Schmidt, former CEO of Convergent Group SA and founder of Bondeko MB (exclusive distributor of Convergent Group in Africa); Carlos Garcia, technical and sales for ADI Group (Spanish distributor for Convergent Group); and Amritpal Singh Sura, external consultant for flooring treatments, former distributor of Convergent products in the Middle East.

    “A number of projects we were doing in the Middle East required protection,” remarked Sura. “Longevity of protection requires a system which basically impregnates and becomes a densified surface as opposed to something which is topical and lifts off due to moisture migration. I found that being exposed to Convergent, it was important to stay focused on those systems in the Middle East. Jean-Claude, Mputu and I met several times in Dubai and there was emphasis on providing systems which were affordable and still ending up having a robust, lasting longevity of product. So you are not spending money all the time in order to maintain the finishes which you have already paid for.”

    Over the course of the session, the participants guided the audience through the potential of cutting-edge lithium silicate technology for enhancing the protection of concrete surfaces, maximising cost-effectiveness and meeting sustainability targets. 

  • In a comprehensive webinar hosted by African Review, a panel of professionals associated with Convergent Group explored new generation lithium silicate technology and why it is emerging as the optimum solution for concrete floor protection.

    Robert Daniels, editor of African Review, was joined by Jean-Claude Biard, CEO of Convergent Group; Mputu Schmidt, former CEO of Convergent and founder of Bondeko MB, an exclusive distributor of Convergent; Hicham Sofyani, president of Texol; Carlos Garcia, technical and sales for ADI Group; and Marc Puig, commercial manager of Comace Import.

    Each providing a unique angle, the panellists combined to provide a masterclass around concrete treatments and the increasing challenges around them, explaining to attendees how to choose the right formula for their requirements and touching on issues such as why lithium densifiers are better than sodium and potassium densifiers. 

    Throughout the session, those watching were treated to informative case studies showcasing how Convergent eco-friendly products are increasing abrasion resistance, raising ease of maintenance, and ensuring the highest quality gloss retention. 

    By the end of the webinar, a majority of attendees (many of which had not had much experience with Convergent) expressed their interest in using the company’s new generation lithium silicate technology with the rest indicating their desire to learn more about Convergent and its products. Watch the webinar, in full, to discover why viewers were convinced and learn more about advanced floor care solutions for your operations.

  • Presenting on an African Review-hosted webinar, Martin Provencher, global industry principal for mining, metals and materials at AVEVA, explored the digital transformation of mining operations and its impact on sustainability.

    “Sustainability is becoming a key aspect for mining operations,” remarked Provencher. “If we look at the latest EY research on the top ten business risks and opportunities for mining and metals globally in 2023, ESG remains at the top. Of course, most companies have environmental goals or are expected to reach a net zero emission by 2050, which is a pretty aggressive target. Many of them are targeting 30% reduction by 2030; seven years from now. So there is a lot of action that needs to take place quickly to get there. It is possible to get there, but we need to make sure we are doing this correctly.”

    Fast becoming a huge part of ESG initiatives is fleet electrification where particular progress is being made in underground mines. While some countries are certainly more advanced than others here, Provencher noted that 40% of total emissions from the mining industry come from diesel trucks, making EVs a very attractive low-hanging fruit for companies to pursue. 

    There are, however, a number of challenges associated with bringing in electric vehicles which remains a barrier for introduction. One of the predominant reasons, is the limited range of EVs against diesel counterparts. To mitigate this, Provencher continued, data management is key and ensuring a strong grasp of real-time information coming in will show operators when machinery needs to be charged, allowing them to plan effectively for maximum efficiency on site.  

    Indeed, this is but a small advantage that digitalisation can bring to the mining industry as it grapples to meet ESG goals while achieving production targets. By getting a better grip of their data and using it to empower tools such as artificial intelligence, advanced analytics and machine learning, companies can achieve tangible benefits such as reduce downtime, enhance worker safety, cut operating costs and, of course, ensure compliance with environmental regulations and targets. 

    Through the course of the webinar, Provencher outlined this in more detail and explored AVEVA’s suite of cutting-edge software solutions, specifically designed to help mining companies make progress on their digitalisation journey and empower their operations. 

    Watch the full webinar, completed with detailed case studies and an insightful Q&A session.

  • Convergent, in association with African Review, has held a detailed webinar exploring the usage and effectiveness of lithium silicates and densifiers over traditional methods of concrete surface management which often struggle to meet the increasing challenges posed by concrete surface management.

    Convergent experts including Mputu Schmidt, CEO of Convergent; Carlos Garcia, product manager end-user solutions, construction chemicals, Spain and Portugal for the RD Group; Matteo Mozzarelli, CEO of concrete Solutions Italia; and Jean-Claude Biard, global senior executive for the Convergent Group, presented across the session. 

    Together, they delved into the latest cost-effective application methods for long lasting finishing of concrete that can help reduce maintenance costs and avoid unexpected repair action. In addition, they examined the advancements in technologies that can sustain increased abrasion resistant stains and ensure gloss retention to the highest quality. 

    As part of the webinar, the representatives explored case studies including a case in DRC where a medical centre had been constructed with a low-quality concrete floor. The customer was considering completely replacing the floor but instead, Convergent put forward a special treatment with its 244+ Pentra-Sil lithium hardener, densifier and sealer. With this solution, Convergent can increase the hardness of a surface by up to 40% and therefore saved the customer significant recuperation costs over a complete replacement. Convergent were happy to report that the solution was perfect for the facility and the customer was pleased to avoid the extra construction work that would have been required for a complete replacement. 

    Watch the full webinar, including more information about Convergent’s innovative solutions.

Top Stories

Grid List

Energy

Daystar Power Group expands solar installations across Nestlé facilities in Côte d’Ivoire, Ghana and Senegal

Energy

Daystar Power Group has strengthened its energy partnership with Nestlé across West Africa, with solar installations now fully operational at four manufacturing facilities in Côte d’Ivoire, Ghana and Senegal

The projects bring Nestlé’s total installed solar capacity across these sites to 6,884 kWp, close to 7 MW, making it one of the region’s largest commercial and industrial solar partnerships.

The four facilities, including two sites in Abidjan, one in Tema and one in Dakar, are now operational. Each solar system has been customised to match the specific grid conditions and operational requirements of its respective location.

“Nearly 7 megawatts across four Nestlé facilities is a number we are proud of, but what it represents matters more than the figure itself. It means that one of the world's most demanding manufacturers has tested our model, trusted it, and come back. Our job now is to keep earning that, across every market where industry needs energy it can count on,” added Yischai Beinisch, CEO, Daystar Power Group.

From one site to four sites

The collaboration began with a single installation before expanding across three countries and four manufacturing facilities. In Côte d’Ivoire, Daystar Power has delivered 3,447 kWp of solar capacity across two Abidjan sites. Ghana’s Tema factory now operates with a 2,547 kWp system, while Senegal’s Dakar facility has an 890 kWp installation.

Each project has been designed to deliver measurable environmental and social benefits, including lower greenhouse gas emissions and improved energy resilience. The systems are tailored to local grid conditions and operational demands, providing reliable clean energy access while supporting local development and contributing to Nestlé’s publicly stated net-zero commitments.

“This investment reflects our commitment to building a business that not only grows but does so responsibly. By advancing solar energy projects in Ghana, Côte d'Ivoire, and Senegal, we are embedding sustainability into our growth, reinforcing our role as a force for good, creating long-term value for communities, and ensuring that our footprint actively contributes to a cleaner, more resilient future,” stated Samer Chedid, CEO, Nestlé Central and West Africa Region.

A footprint that keeps growing

Nestlé’s manufacturing network continues to expand across West Africa, including markets where Daystar Power has established strong operational capabilities. With projects now spanning three countries and nearly 7 MW of installed solar capacity, the partnership has created a foundation to support future clean energy expansion.

 
 

Elmed Project advances Europe-Africa power link

Gensets working in Algeria (Image source: FPT)

Construction

Togo, Benin border highway set for upgrade (Image source: Adobe Stock)

Construction

The African Development Fund (ADF) has approved a US$59.8mn loan to support the rehabilitation of a key transborder road section linking Benin and Togo

The project forms part of efforts to boost regional trade and economic integration across West Africa.

The financing will fund the rehabilitation of 78.8 kilometres of road between Kara and Kabou along the Benin-Togo border as part of the first phase of the Transit Roads and Transport Facilitation Project on the CU18 corridor.

The project is co-financed by the ADF, the concessional lending arm of the African Development Bank (AfDB), the Islamic Development Bank (IsDB), the West African Economic and Monetary Union (WAEMU) and the governments of Togo and Benin.

“This vital corridor will help strengthen economic competitiveness, accelerate the opening up of the inland areas of Benin and Togo, and consolidate sub-regional integration,” said Lamin Barrow, director general for West Africa at the AfDB.

The project includes the upgrading of the corridor stretching from the Benin border at Ouaké through Kémérida, Soundjina, Kara, Djamdé and Kabou into a 3.5-metre dual carriageway, with a six-lane section through the city of Kara.

It will also support the construction and rehabilitation of socio-economic and educational infrastructure, strengthen transport services and logistics along the corridor and introduce measures to reduce trade barriers and improve traffic flow.

Of the total ADF funding, US$50.3mn has been allocated to the Togolese section of the corridor, while the Beninese section will receive US$9.5mn.

Capacity-building programmes for various project implementing agencies and other groups are also planned.

Poor road conditions and high transport costs have long constrained economic activity and mobility in the region, disproportionately affecting vulnerable populations, particularly women engaged in cross-border commerce and market gardening.

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Strong African demand for compact excavators (Image source: Wacker Neuson)

Tuboshu machines at WAMPEX 2026 in Accra (Image source: HMD Ghana, Tuboshu)

Mining

WR receives Namibia’s first Liebherr TA 230. (Image source: Liebherr)

Mining

In a significant achievement, Namibian plant hire and earthmoving equipment company Windhoek Renovations Plant Hire (WR) has received Namibia’s first-ever Liebherr TA 230 articulated dump truck (ADT)

The unit was handed over on 8 April 2026, marking WR’s strategic move towards expanding its Liebherr ADT fleet offering.

Alex Wirtz, technical service and sales manager at Windhoek Renovations Plant Hire, and Tendayi Kudumba, Earthmoving general manager at Liebherr-Africa, were present during the handover of the TA 230.

A long-standing supporter of Liebherr equipment, WR already operates a fleet of around 30 Liebherr machines. The company has now strengthened its fleet with the 28-tonne payload TA 230 articulated hauler, alongside a 21-tonne Liebherr R 920 Litronic crawler excavator.

These new additions complement WR’s extensive Liebherr fleet, which includes excavators such as the A 904 C, A 924 C, R 920, R 926 C, R 934 B, R 954 C, R 974 B and R 984 C, wheel loaders including the L 550 and L 580, as well as crawler dozers PR 744 and PR 764. The expanded fleet reflects WR’s continued confidence in Liebherr and its long-standing partnership with Liebherr-Africa.

Established in 1985, WR is a family-owned Namibian company that has grown into a recognised player in the earthmoving and plant hire sector. Operating nationwide, the company manages a fleet of 70 machines and serves industries including mining, contracting, road maintenance, demolition and hard rock excavation. Led by founder Robert Wirtz and his son Alex Wirtz, WR combines decades of experience with a modern approach to plant hire solutions.

Living up to expectations

Following delivery, the Liebherr TA 230 has been deployed at a gold mine near Karibib, where it is being used to transport fill material for the construction of a slimes dam. According to Alex Wirtz, the machine has already demonstrated the performance expected from it.

“WR Plant Hire is proud to already have this machine operating on site, where it has certainly lived up to expectations. The performance, reliability and production output delivered so far have been nothing short of impressive,” he says. “Investing in world-class equipment like the TA 230 is part of our ongoing commitment to offering our clients the highest standards in earthmoving and mining operations across Namibia,” added Wirtz.

Why Liebherr?

Although WR already operates more than 30 Liebherr machines, Wirtz explains that adding the TA 230 was a natural step aligned with the company’s long-term strategy of investing in high-quality, high-performance equipment. The new articulated dump truck further enhances WR’s diverse fleet and supports its focus on delivering advanced solutions to customers.

“The introduction of the new-generation ADT allows us to offer enhanced efficiency, reliability, and performance on site, while giving our clients the opportunity to experience and benchmark this machine against other leading brands in the market,” he said.

Support is a key factor

Beyond the quality and performance of Liebherr equipment in demanding Namibian conditions, Wirtz highlights Liebherr-Africa’s aftermarket support as a key reason behind WR’s continued partnership with the brand.

“The Liebherr Africa team has consistently provided excellent support over the past 30 years. From sales to technical assistance, the level of service we receive makes a real difference. When you operate a fleet of this size, reliability and support are critical – and Liebherr delivers on both,” commented Wirtz.

Concluding, Tendayi Kudumba, General Manager of Earthmoving at Liebherr-Africa, emphasises the importance of aftermarket services in ensuring equipment performance and customer success.

“Aftermarket support is critical in plant hire and earthmoving because it directly impacts machine uptime, safety, operational efficiency and long-term asset value.”

“In industries such as mining and plant hire, equipment downtime is out of the question, and OEM support – including genuine parts stockholding and technical support – is key to ensuring that machines operate at peak performance, even under extreme conditions, allowing our clients such as WR to run profitable operations,” concludes Kudumba.

Atlas Copco launches portable emergency trash pumps. (Image source: Atlas Copco)

BCM Group wins US$400m Tulu Kapi contract, supporting Ethiopia’s major gold project with comprehensive mining services

Logistics

Gabon begins Kobe-Kobe deep-water port development to boost mining exports. (Image source: Présidence de la République Gabonaise)

Logistics

Gabon’s president and head of state, Brice Clotaire OLIGUI NGUEMA, has officially launched construction works for the Kobe-Kobe deep-water port in Nyonie, located in the Komo-Ocean department

The inauguration ceremony marked a significant milestone for the country’s infrastructure development agenda and brought together government officials, administrative authorities, legislative representatives, traditional leaders, and members of the diplomatic community accredited to Gabon.

The deep-water mineral port project follows a tripartite agreement signed on 23 April 2026 between the Gabonese State, Africa Global Logistics (AGL), and the Algest Investment Bank group. With the commencement of construction, the project has moved into its implementation phase.

Located along the Atlantic coast in the Estuary province, the large-scale development will cover approximately 500 hectares. The project includes a mineral port with four berths, a 535 km mineral railway line, the 400 MW Booué hydroelectric dam, and infrastructure supporting the Belinga iron mine, which is expected to reach a production capacity of 100 million tonnes of iron annually.

The integrated infrastructure network will provide a connection between mining production areas, railway facilities, and the port platform, enabling the transport and export of processed mineral products to international markets.

The Kobe-Kobe project reflects Gabon’s broader ambition to develop, process, and maximise the value of its natural resources at a regional level. It aligns with the Head of State’s vision of creating strategic infrastructure that supports resource extraction, industrial processing, and exports while promoting economic transformation, employment creation, territorial development, and greater industrial sovereignty.

Through the development of these interconnected infrastructures, the project is expected to generate more than 9,000 direct jobs and 100,000 indirect jobs by 2030.

The initiative has attracted investment and expertise from partners across multiple regions, bringing together companies involved in infrastructure, rail development, energy, mining, and mineral marketing. Key partners include AGL for infrastructure, China Railway for railway development, EDF Synohydro for energy infrastructure, Tragigura for international marketing of minerals and processed products, and Fortescue for mining and industrial expertise.

The project further reinforces Gabon’s position as an attractive investment destination supported by strong institutions, political stability, and openness to international partnerships.

The development of these strategic projects represents the implementation of the Head of State’s vision for Gabon’s economic and industrial transformation, with the objective of creating value, generating employment, strengthening competitiveness, and positioning the country as a centre of excellence in Central Africa and beyond.

Advanced LNG Vessel makes Suez Canal debut. (Image source: Suez Canal Authority)

Arua Airport set for transformation. (Image source: AfDB)

Finance

Finance boost for Africa’s supply chain sector (Image source: Adobe Stock)

Finance

Standard Chartered and the International Finance Corporation (IFC) have announced a new risk sharing facility aimed at strengthening supply chains across Africa

The partnership will introduce supply chain finance solutions in eight markets – Ivory Coast, Egypt, Ghana, Kenya, Nigeria, South Africa, Tanzania and Zambia – supporting companies in key sectors such as agriculture, healthcare and manufacturing.

The facility aims to help ensure suppliers get faster payments, freeing up working capital to improve production, pay wages and hire.

The risk-sharing facility will cover up to US$300mn in supply chain and trade finance assets originated by Standard Chartered in Africa.

It comprises a range of underlying supply chain financing instruments – such as payables finance, receivables discounting and pre-shipment finance programmes – to help smaller firms get paid earlier, reduce the cost of working capital, and invest in growth.

“This US$300mn facility with IFC underscores our shared commitment to strengthening Africa's supply chains and enabling sustainable business growth,” said Dalu Ajene, chief executive and head of coverage, Standard Chartered Africa.

“As a super-connector bank with deep expertise across key trade corridors linking Africa to Europe, Asia, the Middle East and the Americas, we are uniquely positioned to channel capital and innovation into the real economy. By expanding access to supply chain finance, we are helping African companies unlock liquidity, manage risk, and invest with confidence.”

Ajene said the collaboration unites Standard Chartered’s cross-border expertise with IFC’s development mandate to empower businesses – from major corporations to smaller local suppliers – “to engage more actively in regional and global trade, fostering job creation and promoting inclusive growth.”

IFC will provide guarantees for up to US$150mn from its own account, with US$100mn committed as the first tranche under the scheme, to support transactions in both US dollars and selected local currencies.

Over the next three years, the partnership is projected to enable about US$1.9bn in supply chain finance transactions, providing access to finance for firms across Africa.

It aims to support more than 500 suppliers, including small and medium enterprises (SMEs), in both domestic and global value chains, with the potential to indirectly benefit over 1 million farmers.

“Supply chain finance is among the fastest ways to narrow the growing finance gap that businesses, particularly small and medium enterprises, are facing in emerging economies,” said Mohamed Gouled, IFC’s vice president, products & clients.

“By partnering with Standard Chartered to support companies at the center of strategic value chains, we can unlock much-needed working capital at scale for businesses across Africa, including smaller firms and farmers, making supply chains more competitive and boosting job creation.”

According to IFC, global demand for supply chain finance has surged – in 2025, the estimated volume reached about US$2.7trn, showing an 8% increase year-on-year.

Yet supply chain finance has not scaled at the same pace in emerging markets, it says, especially in lower income and fragile contexts, largely because commercial banks tend to focus on developed markets.

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Manufacturing

Nearly 40,000 configurations available - each truck is built to meet specific customer needs, making every unit virtually unique. (Image source: IVECO)

Manufacturing

At the heart of IVECO’s industrial operations is its Madrid facility, the only manufacturing site in Spain dedicated to heavy-duty industrial vehicles

The plant produces the company’s complete heavy truck range for international markets including Italy, Germany, Spain and Turkey.

Covering 374,000 m², the facility is built around a 1 km main assembly line and is capable of delivering close to 40,000 different vehicle configurations. With 267 core models and more than 2,800 customisation options available, production is designed around highly specific customer demands. On average, the same truck configuration is assembled just three times annually.

“Every truck we build is essentially a one-off, custom-made to meet specific requirements,” commented José Manuel Jaquotot, director of IVECO’s Madrid and Valladolid plants.

“Each vehicle has a unique identifier that allows us to track it from cab production in Valladolid to final assembly in Madrid, ensuring full traceability and quality.”

Manufacturing operations at the Madrid site rely on a flexible and tightly coordinated production system supported by automation and intelligent logistics. Automated Guided Vehicles (AGVs) transport units across the line, enabling takt times to shift according to the complexity of each build while maintaining uninterrupted workflow across the plant.

Truck cabs arrive from the IVECO Valladolid Plant already painted and welded before being fully equipped in Madrid with dashboards, seats, bunks and airbags. The dashboard assembly process alone includes more than 100 electrical checks and is managed on a separate production line because of its technical complexity.

A major milestone in the process is the integration of the chassis and cab, commonly referred to as the “marriage” stage. Once combined, the vehicle progresses through the fitting of exterior parts, wheel installation and a series of final inspections. These include leak detection, geometry calibration and full functional testing before completion.

The site’s workforce remains central to its operational success. More than 2,700 employees support production activities, bringing the expertise and adaptability required to manage constant product evolution. During 2025, the plant successfully introduced ten new launches.

Sustainability also plays a defining role across operations. The Madrid facility operates entirely on renewable electricity and, in 2025, recycled almost 90% of the water used throughout production processes. Alongside the Valladolid plant, the site forms part of Iveco Group’s broader sustainability strategy and participates in a solar self-consumption initiative with Edison Next Spain, a project expected to help prevent around 500 tons of CO₂ emissions every year.

IVECO’s focus on decarbonisation extends beyond the vehicles themselves to the manufacturing ecosystem behind them. The Madrid plant reflects this broader ambition by combining advanced production technologies, large-scale customisation and sustainable industrial practices in one integrated operation.

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