Solar now provides 20% of wheel manufacturer’s energy needs

The energisation was celebrated at Maxion Wheels South Africa’s 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 tonnes a 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.

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 owing to global trade barriers, growing competition and decarbonisation requirements.

For manufacturers such as Maxion Wheels, where electricity is one of the largest input costs owing 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.

As the world's leading manufacturer of steel and aluminium wheels, Maxion Wheels produces approximately 50 million wheels a year across its 31 locations on five continents. The Johannesburg plant produces high-precision aluminium wheels for major automotive OEM customers in South Africa.

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.

“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,” says Milos Despotovic, Managing Director of Maxion Wheels South Africa.

“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,” he states.

“We thank Maxion Wheels for entrusting Terra Firma as their energy partner to bring this project to life,” says Grant Berndsen, CEO, Terra Firma. “Together, we’re demonstrating how solar power helps to enable long-term sustainability, resilience and global competitiveness for South Africa’s automotive manufacturing sector.”