BMW Group will begin series production of its new iX3 EV in late October at its newly constructed plant in Debrecen, Hungary, marking the start of production for the first model in the company’s Neue Klasse lineup.
The Debrecen facility represents BMW’s iFactory vision, designed as a digital-first manufacturing plant that operates without fossil fuels. “The start of series production for the BMW iX3 signals a new era of automotive manufacturing,” said Milan Nedeljković, BMW AG board member responsible for production. “Our new plant in Debrecen has been designed and built fully in line with our strategic vision of the iFactory.”
The plant was developed using digital planning from the outset, with virtual production beginning in March 2023 in BMW’s Virtual Factory system. This approach allowed engineers to test operations digitally before installing production lines in the physical buildings, matching their digital twin specifications.
Production of the iX3 will generate approximately 80kg of CO2 emissions per vehicle, representing a two-thirds reduction compared to existing BMW models. The Debrecen plant alone will produce around 90% fewer emissions per vehicle compared to other BMW facilities, generating about 34kg of CO2 emissions when operating at full capacity.
“We have taken on the challenge of building a completely new vehicle as the first job at an entirely new plant – and doing so in the leanest, most efficient way possible,” said Hans-Peter Kemser, head of BMW Group Plant Debrecen. “We have simplified processes, reduced complexity, digitally validated each individual operation and systematically leveraged expertise across our global network. The result is this plant, with its efficient production, innovative processes and the flexibility to integrate additional models.”
The facility operates exclusively on renewable electricity during normal production, making it BMW’s first car plant to avoid fossil fuels entirely. A 50-hectare on-site solar system will supply about 25% of the plant’s annual power needs, with surplus energy stored in a thermal storage system holding 1,800 cubic meters of water with 130 MWh capacity.
The paint shop incorporates an energy recovery system that delivers additional energy savings of up to 10% by capturing waste heat from compressed air supply, drying ovens and cooling systems. This recovered heat is used to preheat water circuits throughout the facility.
BMW has equipped the plant with its AIQX artificial intelligence platform, which uses sensors and cameras along production lines to automate quality processes. The system provides real-time feedback to workers and enables vehicles to participate as connected components in the plant’s Internet of Things ecosystem.
The facility employs more than 2,000 workers and serves as a network plant, combining practices from BMW facilities worldwide rather than replicating a single primary plant design. Between now and 2027, the technologies developed for the Neue Klasse will be integrated into 40 new models and model updates across BMW’s lineup.
