Mercedes‑Benz Vans marks a new era with VLE production at Vitoria
Mercedes-Benz Vans has launched production of the all-new VLE on the VAN.EA modular platform at its Vitoria plant, which has undergone a two-year transformation programme of its production operations
Mercedes‑Benz Vans has started production of the new VLE on the all‑new VAN.EA platform at its Vitoria plant, a launch Thomas Klein, Head of Mercedes-Benz Vans, described as “the beginning of a new era.” The programme introduces a new modular platform architecture and significant factory modernisation with a strategic shift toward premium, electrified vans — a move, the OEM said, that is designed to secure long‑term supplier stability, global market reach and an ambitious production ramp up.
Plant modernisation and capacity
The start of VLE production follows a 2-year concentrated investment and transformation programme at the Vitoria plant. Klein highlighted the scale of the factory changes: “We installed a new bodyshop, new technologies and a new paintshop. I'm exceptionally proud of what the team has achieved here in terms of transforming the plant.” Plant Manager, Bernd Krottmayer, framed the investment as part of a broader digital and modernisation push, also noting that the plant now has the most modern bodyshop and paintshops in the network. The VLE body-in-white differs from current production models by utilising a high percentage of aluminium parts, including a large diecast rear module, which required new joining technologies and processes to be added to the plant.
A single line approach to assembly
Although the VLE platform is entirely new, the team at Vitoria have upgraded the existing, physical assembly line and supporting digital systems to integrate the VLE into the current V series production flow. This has required considerable changes to the line with Krottmayer noting that 80% of the main assembly facilities have been changed without interruption of ongoing production. He emphasised the need for flexibility, managing different platforms and powertrains being a key factor in the integration of the VLE, as existing V series production continues.
Vitoria’s long experience of V series production has positioned it as a global hub for the VLE family. The facility has a capacity for approximately 150,000 vehicles per year and currently operates a two‑shift model at high utilisation. Klein said the plant is preparing to scale up production to meet demand: “We currently operate in a two shift model at full capacity … and obviously we are now busy ramping up to a third shift to integrate the VLE and the derivatives …” Further production of the VLE is planned at the company's Fuzhou plant in China, scheduled to begin at the end of this year, this plant will produce vehicles specifically for the Chinese market.
Supplier localisation and a modular platform
A central pillar of the manufacturing approach is strong local supplier integration. Klein underlined the plant’s supplier footprint and local dependence: “There are approximately 1450 suppliers supplying Vitoria, of which 800 are from Spain … more than half of what, what comes to the factory comes from Spain.” He cited specific local sourcing examples to emphasise the regional supply chain’s role: “Body parts of the VLE, are being produced by Gestamp … The seats are being produced locally by Forvia.”
At the heart of the VLE strategy is the VAN.EA modular architecture. Mercedes described the platform as intentionally designed to increase commonality across derivatives and to reduce disruption for suppliers as the company transitions to electrified products.
Mercedes noted that this common‑parts approach serves multiple strategic objectives. It supports the supplier transition from internal‑combustion to electric vehicles, preserves local employment levels, and helps secure predictable production flows as the OEM scales VLE volumes and introduces derivatives. Klein reiterated how the architecture supports both passenger and commercial derivatives: “We obviously plan to also introduce commercial vans on the basis of the same architecture and some of that may also be produced here in Vittoria.”
Battery sourcing is another critical element of the plan. Klein provided specifics on battery supply arrangements: “The battery supplier CATL is currently ramping up its production facility in Hungary … so we have interim supply through other sources from their production network.”
Product positioning and engineering focus
Mercedes positions the VLE as a passenger‑oriented, premium van that bridges the comfort of a limousine with the space of a van. Andreas Zygan, Head of Development at Mercedes Vans, outlined that ambition succinctly: “Our target was really to combine the space of a van with … the driving comfort of a Mercedes Benz limousine.” Zygan called the VLE a market game‑changer for the brand’s passenger vans positioning the VLE as a “grand limousine.”
Engineering priorities reflect that positioning. Zygan emphasised safety and customer protection as important design considerations, noting the VLE’s highly engineered structural safety standards.
Derivative plans and premium ambitions
Klein signalled the brand’s intention to broaden the VLE family beyond the base model. “We plan to do an upscaled version, the VLS … there will be also a Maybach coming … All these vehicles will be integrated here in Victoria.” That derivative plan demonstrates Mercedes’ intent to use the VAN.EA architecture to fill premium and upscale segments of its van business, consolidating production of a range of derivatives at Vitoria.
Starting a new era
Mercedes‑Benz Vans is treating VLE production at Vitoria as a strategic shift. The VAN.EA platform aims to deliver modularity and commonality to stabilise supply chains and enable a family of premium derivatives, while the upgraded Vitoria plant provides the digitalised, flexible capacity to manufacture those vehicles at scale. As Klein put it: “I would call it the beginning of a new era.”
