List of region-based automotive plants

Today the automobile and automotive components manufacturing cluster comprise of 25 manufacturers.

Kaluga automotive cluster includes 3 OEM plants:

ООО Volkswagen Group Russ, ООО PCMA Rus, ZAO Volvo Vostok; 7 car brands:  Volkswagen, Skoda, Volvo, Renault, Peugeot, Citroen, Mitsubishi. Currently, the automotive industry sector of Kaluga Region employs more than 12 thousand people.

1. Volkswagen manufacturing facilities operate since 2007. The plant currently operates in three shifts, six days a week. As of January 2013 the company employed 6100 workers. Current model range comprise of 6 models. 4 of them are manufactured at ООО Volkswagen Group Russ from CKD kits (Volkswagen- Polo sedan, Tiguan; Skoda - Fabia, Octavia), 2 models — from SKD kits (Volkswagen- Touareg,  Multivan). In 2012 the plant produced 180 193 cars. In May 2011 Volkswagen signed an agreement on “industrial assembly mode” with the Ministry of Economic Development of Russia. On November 21, 2012 Volkswagen celebrated the production of its 500,000 vehicles at its Kaluga plant.
2. On December 11, 2012 Volkswagen held a groundbreaking ceremony at Volkswagen AG engine plant site. It is planned to produce 150 000 engines per year (about 600 engines per day). Depending on the economic situation projected capacity of the plant may be increased to 1000 engines per day. It is planned to produce 1,6 liter EA211 gasoline-powered engine series. The plant will have cylinder block, cylinder head and crankshaft machining lines, as well as engine assembly lines. Fully-assembled engines will be delivered to the company's plant in Kaluga and the assembly line in Nizhny Novgorod. The new production facility will create up to 450 new jobs. The total investment volume under the agreement will amount to 200 million euros.
3. ZAO Volvo Vostok – a company owned by Volvo Trucks – operates since January 2009. It is planned to produce about 15 thousand trucks per year (10 thousand Volvo trucks, 5 thousand Renault trucks). Model range: Volvo FH, FM, FL; Renault Premium, Kerax. Today Volvo plant in Kaluga is the most up-to-date production facility among Volvo Trucks plants in the world. In 2010 the plant released 1236 production units; in 2011 – 5067 trucks. The plant produces more than 24 cars per day. As of January 2013 the plant employs 715 workers. After the plant is operating at “full capacity” the number of employees will be increased to 1000 workers.
4. Currently Volvo Construction Equipment is building a new excavator manufacturing facility at the site of IP Kaluga-Yug plant.  Manufacturing facility opening is scheduled for May 2013. An opening ceremony took place on August 29, 2012 to introduce Volvo Customs Department. Customs clearance area equals to 2000 sq. m. (clearance equivalent is up to 135 trucks per day). Today it amounts to 55 trucks per day.
5. On April 23, 2010 Peugeot Citroen and Mitsubishi (OOO PSMA Rus) launched their joint production facility. Production capacity is 125 000 vehicles per year. The manufacturers project to reach full capacity by 2013. The estimated investment volume for the entire duration of the project will be about 19 billion rubles. As of January 2013 investments totaled more than 13 billion rubles. The plant's products are exclusively designed for the Russian market. Production volume in 2012 amounted to 40789 vehicles. The number of employees as of January 2013 was about 2700. The product range represents 3 brands: Peugeot, Citroen, Mitsubishi. Vehicles are manufactured from CKD kits (CKD phase was completed in July 2012): Peugeot 408, Mitsubishi Outlander. Another new model – Citroen C4L – will be launched in March 2013, and one more model in July – Mitsubishi Pajero Sport.

 Auto components manufacturers, whose key customer is Volkswagen plant in Kaluga, are located in IP Grabtsevo which is very close to OOO Volkswagen Group Russ production facilities:

1. Magna Technoplast (bumpers, front modules). The official opening was held on October 28, 2010. The project investment volume amounted to over 44 million euros, the number of employees – 470.
2. YAPP Rus Automotive Systems (plastic fuel tanks). The project investment volume is 640 million rubles. The number of employees engaged in production – 130.
3. Benteler Automotive (suspension components). The project investment volume is over 1 billion rubles, current number of jobs – approximately 360.
4. Visteon Rus (interior components). Number of employees — 60.
5. Gestamp-Severstal Kaluga (body components). The total project investment volume in Kaluga Region amounts to 3,8 billion rubles. Currently the company employs over 250 workers.
6. Severstal-Gonvarri-Kaluga (service center). Investment volume amounts to 1,6 billion rubles. Construction of OOO Severstal-Gonvarri-Kaluga Steel Services Center was launched in May 2009. In 2011 the company reached its design capacity of 170 thousand tons of rolled metal products per year. The number of jobs — 60.

Besides, the following companies are located at brownfield sites:  

1.  Lear – car seats manufacturer, occupies 10 000 square meters of leased manufacturing facilities. The project investment volume equals to 4 million euros. The number of jobs created by the project is 250.    
2.  HP Pelzer Rus occupies 4500 square meters of leased manufacturing facilities, supplies components (noise insulation) for leading automotive companies. The project investment volume equals to 796 million rubles. The company currently employs about 130 workers.
3. Faurecia Automotive Development is represented by several divisions.
4. Faurecia Interior division plans to launch the assembly process in 2013 and to start deliveries to OOO PCMA Rus. The approximate amount of projected investments is 15 million euros. The company plans to create 150 jobs.
5. Faurecia Emissions Control Technologies is building a plant in the territory of IP Rosva to produce exhaust systems. The approximate amount of projected investments is 7,5 million euros. The company plans to create 130 new jobs. The plant will be launched in 2013.
6. Sherdel Kaluga manufactures metal structures of car seats. Its production facilities occupy 2000 square meters of leased manufacturing and warehouse premises located in the territory of Elikor group of companies. The company established business relations with OAO Elmat which provides coating services. Total investments amount to 4 million euros.  The company created 40 new jobs.
7. HT&L Fitting is engaged in tire and wheel assembly. Its production facilities occupy     3500 square meters of leased manufacturing and warehouse premises in the territory of ООО RUS). The project investment volume equals to 3 million euros. The company employs 60 workers.
8. Bozal manufactures automobile mufflers. Its production facilities occupy 3190 square meters leased from ZAO Kaluzhsky Avtoremontny Zavod. The project investment volume equals to 138 million rubles. The company employs 60 workers.
9. Shapers 'Rus is a member company of Shapers' Group, a global mouldmaker with 850 employees worldwide and 6 own factories in different countries (Poland, Germany, India, China, Brazil, France). Shapers' Group manufactures molds weighing up to 50 tones and provides a full range of services from design to production of plastic products model samples.

 In the near future the companies that have signed investment agreements will be added to suppliers list:

1.  FUCHS OIL. Investment in the new project will amount to approximately 20 million euros. About 40 new jobs will be created. The plant will produce a wide range of automotive lubricating oils (engine oils, tractor oils, gear oils, compressor oils), as well as cutting lubricants, hydraulic and hardening liquids. At present the company is building a new plant in the territory of Rosva industrial park. The project is split into two phases. The first phase will be completed by the middle of 2013.
2. Continental Automotive Systems RUS is engaged in the production and delivery of electronic fuel injection and ignition control system components to local car factories. Major product types: engine control units, fuel rails, mass air flow sensor included in the engine control system, oxygen sensors, car alarm system, injectors, fuel modules. An agreement with this company is almost prepared for signing.
3.  Fuyao Glass Industry Group Co Ltd. produces a wide range of automobile glass, including waterproof, bullet-proof, heat-resistant glass and other products, such as silver mirrors and lead-free mirrors. Approximate volume of investments is more than 300 million euros. About 900 jobs will be created. Currently the company is building production facilities in Grabtsevo industrial park on site 4 with an area of 13 ha. Production is scheduled to start in the first half of 2013.
4.  Continental AG decided to build a new tire plant in Kaluga Region. The new plant will be located in Rosva investment park. In January 2013 during the first phase of the project the investment volume amounted to approximately 240 million euros. About 400 jobs are expected to be created by the end of 2013. The facility is expected to produce 4 million tires annually during the first phase of the project.

ООО Betsema Kaluga is primarily engaged inthe production of special vehicles, cars used in the road sector, industrial equipment for cement, steel and chemical industries.

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