IVECO’s Madrid facility stands as Spain’s only production site for heavy-duty industrial vehicles, manufacturing the brand’s entire heavy range for global markets including Italy, Germany, Spain, and Turkey.
Spanning 374,000 square metres, the plant features a one-kilometre main assembly line. Nearly 40,000 vehicle configurations are available – each truck is built to meet specific customer needs, making every unit virtually unique. With 267 base models and over 2,800 customisable options, each truck is tailored to individual customer needs – so much so that the same configuration is produced, on average, only three times a year.
“Every truck we build is essentially a one-off, custom-made to meet specific requirements,” says 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.”
The Madrid plant’s production process is highly flexible and precise, supported by advanced logistics and automation systems. Advanced automation, AGV (Automated Guided Vehicle) systems, and 100% renewable electricity use make the plant a model of efficiency and environmental responsibility. The dedicated AGV system moves vehicles along the line, allowing for dynamic takt time adjustments based on each truck’s complexity – without disrupting the overall flow.
The cab arrives from IVECO Valladolid plant already welded and painted and is fully outfitted in Madrid with components such as the dashboard, seats, bunks, and airbag. The dashboard alone undergoes over 100 electrical tests and is assembled on a dedicated line due to its complexity.
The “marriage” of chassis and cab marks a key moment in the assembly process. From there, the truck takes shape with the installation of exterior components, wheels, and final testing – including leak checks, geometry calibration, and functional inspections.
Beyond technology, the plant’s strength lies in its people. Over 2,700 skilled employees drive excellence and adaptability, managing constant product updates and innovation. The team brings deep expertise and agility to manage continuous product updates. In 2025 alone, the plant handled 10 new launches.
Sustainability is embedded in every step. The Madrid plant uses 100% renewable electricity and in 2025 recycled almost 90% of the water used in production. Together with Valladolid, it leads Iveco Group’s efforts in sustainable manufacturing and is part of a pioneering solar self-consumption project with Edison Next Spain, helping avoid around 500 tons of CO₂ emissions annually.
IVECO’s commitment to decarbonization goes beyond vehicle technology — it extends to how those vehicles are made. The Madrid plant exemplifies this vision: a place where innovation, customisation, and sustainability come together to shape the future of transport.
Watch the video of the IVECO S-Way manufacturing process inside the Madrid plant here.
