The rolling stock segment of Indian Railways (IR) is undergoing a significant transformation marked by technological advancement, manufacturing strength and strategic intent. The focus has shifted from merely replacing ageing assets to developing faster, safer, energy-efficient and globally competitive rail vehicles, increasingly designed and manufactured within the country.
During 2025-26 (till December 2025), IR manufactured a total of 4,342 Linke Hofmann Busch (LHB) coaches, registering an 18 per cent increase over the corresponding period of the previous year, underscoring the accelerated transition towards modern and safer coach designs. The momentum is equally evident in the production of Vande Bharat train sets, with coach manufacturing rising steadily from 216
units in 2022-23 to 410 units in 2024-25, signalling an all-hands-on-deck approach to rolling stock modernisation. Looking ahead, IR plans to introduce Vande Bharat 4.0 by 2027, which is expected to significantly enhance network efficiency. Reportedly, the next-generation train will be equipped with Kavach 5.0, featuring advanced safety systems, and will be designed for a maximum operational speed of 250 kmph, marking a new benchmark in India’s rail mobility ambitions.
Meanwhile, the production of Amrit Bharat coaches has also gathered pace, increasing sharply from 42 coaches in 2024-25 to 383 coaches in 2025-26 (till January 2026), further reinforcing the broader push towards fleet modernisation.
The modernisation drive
IR has accelerated the modernisation of its rolling stock across train sets, coaches and locomotives, with a strong emphasis on capacity enhancement, safety improvements and passenger comfort. A key milestone in this journey was achieved in January 2026 with the introduction of the Vande Bharat sleeper train on the Howrah-Guwahati (Kamakhya) route. The deployment of this semi-high-speed sleeper service is expected to reduce travel time on the route by nearly 2.5 hours. Designed for a maximum operating speed of 180 kmph, the 16-coach train set comprises 11 three-tier AC coaches, four two-tier AC coaches and one first-class AC coach, offering a total passenger capacity of around 823 passengers. To support the expansion of sleeper services, IR is also progressing with the development of dedicated maintenance infrastructure, with the first phase of the Vande Bharat sleeper maintenance facility at Jodhpur, Rajasthan, scheduled for completion by June 2026.
At the same time, IR has undertaken targeted capacity augmentation of existing Vande Bharat chair car services to meet rising passenger demand. Several train sets have already been expanded from eight to 16 coaches, while plans are under way to further increase rake length on select high-density routes, reflecting a data-driven approach to fleet deployment and utilisation. In parallel, IR is also advancing preparations for its first 24-coach Vande Bharat sleeper train, designed to offer higher berth capacity and enhanced onboard amenities, including the provision of a pantry car, to better serve long-distance passengers.
Between 2014 and 2025, IR manufactured more than 42,600 LHB coaches, an 18-fold increase compared to just 2,300 coaches produced between 2004 and 2014. This long-term expansion underscores the sustained focus on modernising passenger services through the widespread adoption of LHB technology, which offers superior crashworthiness, improved ride comfort and lower life cycle maintenance requirements.
On the locomotive manufacturing front, the central government inaugurated the Dahod electric locomotive manufacturing plant along with its first indigenously manufactured 9,000 HP electric locomotive in Gujarat in May 2025. The facility, developed at an investment of approximately Rs 214 billion, is designed to manufacture 9,000 HP electric locomotives for both domestic deployment and export markets. Each locomotive will have the capability to haul 4,600 tonnes of freight, significantly strengthening IR’s heavy-haul capacity. Equipped with a regenerative braking system, it is aimed at improving energy efficiency and enhancing overall freight throughput. The plant has an initial production capacity of 120 locomotives per annum, scalable to 150 units annually.
Meanwhile, production at advanced manufacturing units such as Madhepura is supporting the growing requirements of heavy freight and long-haul operations. Concurrently, safety-focused upgrades are being undertaken, with locomotives being modified to ensure compatibility with the Kavach automatic train protection system (ATPS), aligning rolling stock modernisation with network-wide safety enhancements.
To strengthen the maintenance and safety systems, IR signed an MoU with Dedicated Freight Corridor Corporation of India Limited (DFCCIL) in July 2025 for the deployment of the machine vision-based inspection systems (MVIS). This artificial intelligence and machine learning–enabled wayside technology captures high resolution images of the undergear of moving trains to automatically detect hanging, loose or missing components. Upon identifying anomalies, the system generates real-time alerts, enabling prompt intervention and preventive maintenance. Under the MoU, DFCCIL will procure, supply, install, test and commission four MVIS units, marking a significant step towards predictive maintenance and enhanced operational safety across freight corridors.
IR is also planning to launch Gati Shakti freight trains, which will be manufactured at the Integral Coach Factory (ICF) in Chennai.
ICF will manufacture Gati Shakti freight electric multiple units, semi-high-speed trains designed for transporting e-commerce and fast-moving consumer goods. These trains will be equipped with advanced container handling systems and enhanced crew amenities.
Road to decarbonisation
On the sustainability front, IR has taken decisive steps towards cleaner propulsion technologies and reduced carbon intensity in rail operations. A major milestone was achieved with the manufacturing of India’s first 10-coach hydrogen-powered train set on the broad gauge platform, featuring two 1,200 kW driving power cars and eight passenger coaches, delivering a total installed power of 2,400 kW. Designed for zero tailpipe emissions, the train set emits only water vapour during operation, marking a significant leap towards carbon-free rail mobility. To support its operations, a dedicated green hydrogen refuelling plant is being established at Jind in Haryana, where hydrogen will be produced through the electrolysis process, aligning with India’s broader green hydrogen mission.
In parallel, IR is also advancing transitional fuel solutions. In January 2026, it commissioned its first dual-fuel diesel-liquefied natural gas (LNG) Diesel Electric Multiple Unit (DEMU) at the Sabarmati Integrated Coaching Depot, enabling power cars to operate on both fuels and achieve up to 40 per cent reduction in diesel consumption per trip, along with lower emissions and operating costs.
Building on near-complete network electrification, IR is now steadily moving away from conventional diesel traction, with battery-operated and alternative-fuel trains being prioritised for short- and medium-distance services. The phased withdrawal of diesel locomotives is expected to begin with yard operations, shunting and last-mile freight movements, reinforcing a pragmatic and technology-neutral transition towards
sustainable rail operations.
Make in India, Make for the world
Under the Make in India initiative, IR is leveraging rolling stock modernisation to drive technological self-reliance, sustainability and global competitiveness. The large-scale production of modern LHB coaches, the rapid expansion of indigenous Vande Bharat train sets, and the planned introduction of Vande Bharat 4.0 reflect India’s growing capability to design and manufacture next-generation rail
vehicles domestically.
Parallelly, the near-complete electrification of the broad gauge network has enabled a decisive shift away from diesel traction, with electric locomotives and train sets increasingly dominating operations, while alternative technologies such as battery and hydrogen propulsion are being explored for non-electrified routes. The rapid ramp-up in Amrit Bharat coach production highlights a balanced approach that combines affordability with modern design and improved passenger comfort. Indigenous propulsion systems, control electronics, braking technologies and coach components are increasingly being sourced from Indian suppliers, strengthening the domestic rail supply chain.
On the exports front, IR, in partnership with Wabtec Locomotive Private Limited, has strengthened India’s position under the Make in India and Make for the World initiatives by rolling out Evolution Series ES43ACmi diesel locomotives from the Marhowrah locomotive plant in Bihar for export to the Republic of Guinea. This initiative is part of a contract worth Rs 20 billion, involving the production of 140 locomotives, with phased deliveries continuing through 2027.
Complementing this, Banaras Locomotive Works (BLW) secured an export order through RITES Limited to supply 10 indigenously built 3,300 HP AC-AC diesel-electric locomotives to Mozambique Railways in 2025. RITES is also set to export 18 in-service diesel locomotives to South Africa by March 2026, following suitable modifications for Cape-gauge operations. Together, these developments highlight India’s growing capability to manufacture, customise and supply advanced locomotives for diverse international markets.
The way forward
Looking ahead, IR has set a production target of 4,802 LHB coaches for 2026-27 and has also planned the production of 1,500 additional Vande Bharat coaches by 2029-30. IR is also advancing its “Hydrogen for Heritage” initiative, with plans to deploy around 35 hydrogen fuel cell trains on routes where electrification is difficult or economically unviable. Collectively, these initiatives signal a future where rolling stock will continue to play a central role in capacity expansion, sustainability and India’s emergence as a global railway manufacturing hub.
Simran Kaur
