Rolling stock is the cornerstone of progress for any railway network. With a staggering allocation of Rs 455 billion under Union Budget 2025-26, it is set to enhance the efficiency of Indian Railways (IR) network. Moreover, with the introduction of semi-high-speed trains such as Vande Bharat and Amrit Bharat and high-speed trains in the pipeline, IR has laid an impeccable foundation for the sector’s growth.
As per the Economic Survey 2024-25, the manufacturing of Vande Bharat coaches has steadily increased over the years – from 216 in 2022-23 to 900 in 2024-25 (up to October 2024) – indicating an all-hands-on-deck approach by IR to modernise the rolling stock. The launch of these advanced, indigenously manufactured trains is not only expected to foster innovation and growth, but also lead to a more resilient, competitive and self-reliant railways.
Continuous upgradation of the existing rolling stock
The sector is focusing on introducing new variants of existing trains, such as Vande Bharat and Amrit Bharat, to optimise both passenger and freight movement. The highly anticipated sleeper version of Vande Bharat trains, being manufactured by the joint venture (JV) of BEML Limited and Medha Servo Drives Private Limited, in collaboration with the Integral Coach Factory (ICF), completed the final leg of its trial run on the Mumbai Central-Ahmedabad route of Western Railway in January 2025. The Research Designs and Standards Organisation (RDSO) is expected to issue the final certification after analysing the results of the trial. Further, Northern Railway unveiled an upgraded version of the existing Vande Bharat Express train on the Katra-Srinagar route in January 2025. The train is equipped with an advanced heating system for efficient operation of the air brake system and supply of warm air to the vacuum system, ensuring effective functioning even at low temperatures. Furthermore, in September 2024, IR’s first Kavach-equipped Vande Bharat Express train service was commercially operationalised on the Bhuteshwar-Palwal section under the Agra division.
IR has also announced plans to manufacture a total of 50 new Amrit Bharat version 2.0 trains by 2027. These trains will be an upgraded version of the existing Amrit Bharat trains and will be manufactured at the ICF in Chennai. They will feature 12 enhancements, including semi-automatic couplers, a vacuum evacuation system, an on-board condition monitoring system and an electropneumatic assisted brake system, among others.
In a bid to provide further impetus to the revenue generating freight segment, IR unveiled the first look of the Vande cargo train in September 2024, with the aim to facilitate parcel delivery with exceptional speed and efficiency. Modelled after modern air cargo systems, the Vande cargo train will be equipped with advanced features and security measures. These trains will utilise freight electric multiple unit (EMU) rolling stock built on the Vande Bharat platform and are expected to operate at speeds of up to 160 km per hour (kmph). Additionally, four long-haul trains were successfully operated by joining eight freight trains on the route between Dadri and Deendayal Upadhyay station of the eastern dedicated freight corridor in October 2024. This formation is expected to improve freight operations and benefit Dedicated Freight Corridor Corporation of India Limited.
Moving towards advancement
With a vision of developing a railway system on par with global standards, featuring high-speed and hydrogen-powered trains, the sector is moving in the right direction. In line with this, IR is expected to receive two upgraded versions of Japan’s Shinkansen bullet trains, known as the Shinkansen E10 or Shinkansen Alfa-X. These high-speed trains will be capable of reaching a maximum speed of 400 kmph. Moreover, both Japan and India are planning to roll out these trains simultaneously by 2029-30. Reportedly, the governments of both countries have agreed that India can test and launch its two prototype indigenously manufactured bullet trains in 2027 using the existing high-speed rail infrastructure between Ahmedabad and Mumbai. Meanwhile, as part of IR’s goal to achieve net zero carbon emissions by 2030, the final trial for India’s first hydrogen train is expected to take place in March 2025. The train, designed to carry over 2,600 passengers, will feature eight passenger coaches and three hydrogen cylinder storage coaches. The first power car is expected to be commissioned this month, with the second scheduled for April 2025. A toy model of the train was launched at the RDSO stadium in Lucknow in November 2024.
Additionally, in November 2024, IR announced plans to launch India’s first double-decker cargo liners, with each coach estimated to cost around Rs 50 million. The Rail Coach Factory’s design for these double-decker cargo liners, based on the belly freight concept, has been approved and construction of the prototype is in progress. These cargo liners will feature an executive upper deck, accommodating 46 passengers and the lower deck will have a capacity of about 6 tonnes (cargo mass) and 47 cubic metres (cargo volume), to be utilised for freight storage.
In terms of deploying more futuristic technology, the Indian Institute of Technology Madras (Avishkar hyperloop team) and TuTr Hyperloop Private Limited have completed the construction of India’s first hyperloop test track, stretching 410 m, in December 2024. The technology, still in its nascent stage of development, can transport about 24 to 28 passengers at a speed of 600 kmph inside low pressure vacuum tubes.
Focus on indigenous production of world-class rolling stock components
To build resilient domestic supply chains, the sector has been experimenting and investing in the production of advanced components in India. In January 2025, IR developed a hydrogen train engine with a capacity of 1,200 horsepower (hp). Complementing the Make in India initiative, the engine has been developed indigenously and is one of the most powerful in its category, with other countries operating engines with capacities of 500-600 hp. The engine manufacturing is complete and system integration work is in progress. IR also plans to establish a new coach production facility in Telangana, with an investment of Rs 7 billion. Reportedly, the facility will be located at the railway manufacturing unit in Kazipet and has the capacity to manufacture a total of 600 Linke Hofmann Busch (LHB) passenger coaches, EMUs and locomotives annually. The construction work for the same is in progress and is expected to be completed by August 2025.
Furthermore, IR launched its first pair of WAP-5 aerodynamic (converted) electric locomotives in October 2024, from the test shed of the Chittaranjan Locomotive Works. These locomotives will be used in Amrit Bharat trains by integrating them with the LHB rakes at the ICF. The new variant will feature an impact resistant windshield, real-time information system, remote monitoring system and Kavach 4.0 among others.
The domestic private sector has also stepped up, with the consortium of Ramakrishna Forgings Limited and Titagarh Rail Systems Limited planning to commission their forged wheel plant by March 2026. A total of 72.75 acres of land has been acquired in Tamil Nadu for the plant’s development and the project is now at an advanced stage. Meanwhile, IR has ordered the required machinery, with despatches expected to begin in March 2025.
Notably, global players have also started manufacturing various components through their Indian counterparts. In January 2025, Alstom was awarded a contract of approximately Rs 13 billion to provide Mitrac traction components and other electrical equipment for 17 Vande Bharat sleeper trains to the ICF. The contract will be executed at Alstom’s Maneja facility, with serial production expected to start in 2027, following the expected delivery of the prototype in August 2026. Similarly, in November 2024, Russia-headquartered Transmashholding (TMH) announced plans to invest in train and component manufacturing in India. Reportedly, TMH plans to develop several facilities in India to meet their domestic requirements.
Looking ahead
India’s rolling stock infrastructure is set to reach new heights with a fleet of trains leveraging sophisticated technology. According to the recent budget announcements, IR plans to roll out a total of 17,500 general non-air-conditioned coaches, 200 Vande Bharat trains, and 100 Amrit Bharat trains by 2027-28. Moreover, IR aims to establish a high-speed rail network spanning 7,000 km, capable of supporting trains running at speeds of 250 kmph by 2047.
Further, the domestic manufacturing of rolling stock components such as forged wheels reduces IR’s reliance on other countries, resulting in significant savings in foreign exchange. During 2024-25, IR invested Rs 9 billion to import forged wheels, primarily from China, Russia and Ukraine, which poses risks amid global uncertainties. IR also plans to launch 50 hydrogen trains by 2047 as part of its sustainability initiatives. These innovations in train production are expected to provide India with a competitive edge. For instance, Germany is currently the only country with operational hydrogen trains. The operationalisation of these indigenously developed hydrogen trains in India is likely to create significant opportunities, particularly in terms of first-mover advantage, further facilitating the country’s exports.
