Ford Retools German Plant for VW-Platformed, Europe-only Explorer EV

• Ford is drilling down on its EV investments in America and Europe, as the company reopens its Cologne, Germany, plant as an EV hub.

• With an annual production capacity of 250,000 units, Ford says the first model produced at the plant will be the VW-backed, Europe-only Ford Electric Explorer.

• Beyond EV production, Ford says this factory remodel included upgrades in the name of carbon neutrality, specifically around renewable electricity and steam-based heat.

Ford is taking its EV transition very seriously. From breaking ground on new EV plants in Tennessee and Kentucky to hashing out a charging deal with Tesla, the American manufacturer is signaling its dedication to the future of electric vehicles in the US. But the US isn't the biggest EV market by a long shot, especially compared to Asia and Europe.

Of course, Ford has a plan for that too, as it announces the official opening of its Cologne, Germany, EV plant. Originally opened in 1931, the Cologne Body and Assembly plant has produced everything from the Ford Model A and the Capri to all eight generations of Ford Fiesta, but its purpose within Ford's lineup is set to change. And it's getting a new name too.

Following a $2 billion investment initially announced in 2021, Ford's Cologne Electric Vehicle Center is now open for production. With 308 acres of battery assembly and state-of-the-art tooling and automation now available, Ford says the German facility will have an annual production capacity of 250,000 EVs, starting with the Volkswagen-platformed, Europe-only electric Explorer. European EV buyers can also expect an additional electric sports crossover to be revealed soon, Ford says.

Specific plant improvements include self-learning machines, autonomous transport systems, and instant big data management systems, though Ford claims it doesn't want to supersede human workers at the plant. Even so, Ford is adding cognitive and collaborative robots as well as augmented reality solutions, to "increase efficiencies and data exchange" with other company plants.

The plant retooling fits with Ford's commitment to produce 100% of its European passenger vehicles as zero-emissions capable, all-electric, or plug-in hybrid by 2026. But fulfilling production capacity and planning for new EV models is not the only reason Ford spent billions of dollars to renovate the Cologne facility. Ford says achieving carbon neutrality at the plant was equally important.

"Opening the Cologne EV Center is the start of a new generation of clean manufacturing and electric vehicles in Europe," said Bill Ford, Ford's executive chairman. "This facility will now be one of the most efficient and environmentally responsible plants in the entire industry. I am thrilled to continue working toward a zero-emissions future for our children and grandchildren."

But how exactly does Ford achieve a carbon-neutral automotive plant? Ford says all electricity and natural gas required to operate the facility will be from 100% certified renewable electricity and biomethane, in addition to the construction of new perennial vegetation, wildflower meadows, and insect hotels as well as bat and bird habitats. Ford will also work with local energy providers to offset the corresponding plant heating emissions, as the internal heating is provided through a recycled steam network.

For clarity, Ford says its plant isn't 100% carbon neutral just yet, though it expects full carbon neutrality by 2035. Emissions will be reduced by 60% in 2026, with a regular schedule of independent carbon audits set for the foreseeable future.

Revamping the Cologne plant will allow Ford to push well beyond the 18 million vehicles produced there since 1931. Competing for sales supremacy in Europe, especially EV sales, is no small feat with brands like Volkswagen and Tesla dominating the market. But, with competitive models currently available and more planned, Ford is attempting to save its traditionally popular place within Europe.

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