Toyota reopens plant in Porto Feliz (SP) one year after its destruction by storm

A year after having its roof ripped off by an atmospheric microexplosion, Toyota’s engine plant in Porto Feliz (SP) has resumed producing parts at its original address. The automaker inaugurated a new foundry in the complex, built with metal reinforcements 45% more resistant than those of the previous project.

The disaster occurred on September 22, 2025. Shortly before the storm, the power outage triggered a safety protocol that emptied the main area. Three minutes later, the roof gave way, with no casualties.

Moving to Sorocaba in four days

With precision equipment exposed to sun and rain, the company set up a quick decision room, the “Obeya” of Japanese corporate culture, and transferred the industrial park to a business condominium 11 km from the Sorocaba vehicle factory. There were 622 machines removed, at the rate of ten per day. Thus, a layout work that would normally take four months was completed in four days.

The bottleneck of the temporary shed was electric: the installation only included lighting. The necessary substation, estimated to take ten months of work, was ready in three, with the support of the local concessionaire, and the initial tests ran with portable generators. Production resumed on January 26, 2026.

Priority was the Yaris Cross

engine The foundry suffered losses. Without power, there was a lack of gas for the high-pressure line, and the aluminum solidified, but was recovered. The low-pressure one, responsible for the cylinder head, was lost. To maintain supply, Toyota sent exclusive molds to Japan and Indonesia.

In the emergency complex, the priority was the 1.5 engine of the Yaris Cross, exclusive to Brazil for combining flex hybrid technology and direct injection, with 400 units per day. The 2.0 flex of Corolla and Corolla Cross had the equipment only stored, and the matrix absorbed the demand.

As the Japanese engine is not flex, Porto Feliz exports parts from national suppliers and imports the assembled engine. The forecast is to bring this production back by 2028.