Imagine standing at the edge of a vast, endless manufacturing complex. It feels like you're in a city, not in a factory. This is BYD's electric vehicle super factory in Zhengzhou, China. Covering over 130 square kilometers, it is not only the world's largest electric vehicle factory but also an industrial metropolis that is self-sufficient, possessing the power to redefine global transportation. Previously, we discussed Northvolt Ett, the super factory in Sweden, which is revolutionizing the electric vehicle industry in Europe.

This place never stops. A brand new electric vehicle rolls off the assembly line every 30 seconds. I have never seen a production site with such a strong rhythm of steel, software, and speed.

From Battery to Global Dominance

BYD's journey did not start with cars. In 1995, it began by producing mobile phone rechargeable batteries. This seemingly modest entry point was a calculated step. BYD founder Wang Chuanfu realized the growing importance of energy storage long before other companies in the automotive industry caught up.

In 2003, BYD took what many considered a foolish step. It acquired a nearly bankrupt state-owned car manufacturer, Xi'an Qinchuan. Critics scoffed at the idea of a battery company trying to make cars. But Wang Chuanfu was not following trends; he was creating the future. His vision was a world where batteries could power not only phones but also people and cities.

Initially, BYD produced gasoline vehicles to establish itself in the market. Later, the company began producing hybrid vehicles. By 2022, it completely exited the internal combustion engine car production and focused entirely on electric vehicles. This decision placed it ahead of all traditional automakers, even its main competitor, Tesla.

In 2024, BYD's revenue surged to $107 billion. It has become the world's top-selling electric vehicle manufacturer, delivering over 3 million electric vehicles worldwide. The Zhengzhou factory is the next step in BYD's expansion.

Entering Zhengzhou: The Heart of BYD's Industrial Empire

Zhengzhou is not just a factory, but a turning point. Located in Henan Province, China, the factory is being built in eight stages. As of mid-2025, five stages have already been completed and are in operation. Once fully completed, the factory will cover more area than Manhattan, with an annual production capacity exceeding one million vehicles.

16 fully automated production lines operate around the clock. Artificial intelligence software coordinates every task, from welding the chassis to installing blade battery systems. These robots not only assemble but also learn. Machine vision and predictive analytics continuously optimize each weld, torque, and quality check in real-time.

When operating at full capacity, the factory produces two vehicles per minute. But this is not just about numbers. Each vehicle is scanned by thousands of sensors that detect minor defects earlier than the human eye can.

I walked along one of the production lines and saw robotic arms adjusting their paths during movement to compensate for slight variations in material density. This is not just automation; it is evolution.

Vertical Integration: BYD's Secret Weapon

Most automakers rely on complex supplier networks. BYD has rewritten this model. It produces almost all core components of electric vehicles independently, from semiconductors, drive motors, to battery cells, and even the software that controls them. This level of vertical integration is unique in the industry.

During the global supply chain collapse between 2020 and 2021, while other manufacturers faced shutdowns and delays, BYD continued to deliver vehicles. This reliability earned recognition. Governments, fleet operators, and private buyers noticed it. Trust is crucial, and BYD won trust when other manufacturers failed to meet their promises.

Producing key components in the same factory not only improves quality but also significantly reduces costs. There are no port delays or price increases due to third-party suppliers. Just a fully controlled, unified process.

Blade Battery: BYD's Signature Advantage

The core of BYD's success in electric vehicles lies in its signature "blade" battery. Unlike traditional cylindrical or pouch batteries, blade batteries consist of long, flat lithium iron phosphate (LFP) blades stacked side by side. This structure enhances thermal efficiency, making the battery more stable and significantly reducing the risk of fire.

It has higher density, lighter weight, and lower production costs. Models such as the BYD Dolphin, Seal, and Atto 3 use blade batteries, and these models have established themselves in Europe, Southeast Asia, and Australia.

The next generation of models currently being tested in Zhengzhou are even more ambitious: they will use semi-solid-state batteries, with an estimated range of 800 kilometers and support for 10-minute ultra-fast charging. This is not just empty talk, but a roadmap already in implementation.

A Factory That Feels Like Home: Where 60,000 People Work and Live

You might think that such an automated place would feel cold. Actually, it is not. Over 60,000 employees live and work in the Zhengzhou factory. BYD has built various facilities within the factory, including employee dormitories, elementary schools, clinics, gyms, and parks.

This people-centered planning has a strategic purpose. Employees do not need to commute; they can just walk. They are always ready, yet not far from their families or daily lives. This is to create stability and loyalty.

BYD understands that productivity does not start in the factory workshop, but in the home. And they have put this idea into practice.

Location: BYD's Hidden Advantage

Zhengzhou is not only centrally located but also a logistics hub. It is situated at the intersection of China's major highway and railway systems. A direct freight railway connects the factory to Shanghai Port, shortening export time by 20%.

Adjacent resource areas contain lithium, cobalt, nickel, and rare earth elements—key raw materials for electric vehicle production. BYD not only mines these resources but also refines and processes them in nearby facilities. This means fewer delays, less reliance on imports, and stronger pricing power.

Site selection is not just strategic, but tactical.

One Plant at a Time, Expanding Globally

Even as the Zhengzhou factory operates at full speed, BYD is preparing for global expansion. It holds mining rights in Chile and Zimbabwe to ensure a supply of lithium. In Hungary, a $1.3 billion factory is under construction, targeting the European market. Next comes Brazil, aiming to tap into the growth of the South American electric vehicle market.

This decentralized production model reduces tariff risks and buffers against political instability. But its role goes beyond that, making BYD a supplier rather than just a brand. Currently, multiple automakers purchase BYD's batteries and powertrains for their own models. This turns competitors into partners.

Sustainability Must Be Practiced, Not Just Spoken About

Over one million square feet (about 90,000 square meters) of rooftop solar panels directly power the factory. A closed-loop water recycling system treats all wastewater. Rainwater is collected and filtered for cooling systems, reducing total water usage by nearly 40%.

Every design decision considers environmental impact. Compared to a fossil fuel power plant of similar scale, Zhengzhou saves about 120,000 tons of carbon dioxide emissions annually. There is no greenwashing here, only green engineering.

Looking Ahead: The Factory Shaping the Next Decade

By 2026, the Zhengzhou factory may account for nearly 25% of global electric vehicle production. This is an impressive prediction, but not unrealistic. BYD plans to expand its workforce in Zhengzhou to over 200,000. This number exceeds the population of many cities.

What about the $10 billion investment? It not only shows returns in sales but also in global influence. From European city bus fleets to compact city sedans in Southeast Asia, BYD's influence is growing.

Final Shot

Being in Zhengzhou doesn't feel like visiting a factory, but stepping into the future. Something is being built, tested, and improved every second. You can hear the hum of machines and see the pulse of human ambition. This is not science fiction, but a blueprint for the future.

If you want to understand how the next generation of cars and the cities they will be built in will look, start here.

Source: Incredible Construction

Original: https://www.toutiao.com/article/7523434118698009122/

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