To reduce dependence on foreign suppliers, Indian Railways (IR) has embarked on a journey to manufacture equipment, develop technological capabilities and provide services of global standards in the country. In line with this, IR, in collaboration with various private manufacturers and technology providers, has made significant strides in indigenising its operations. This includes initiatives such as the production of semi-high-speed trains, trains that run on cleaner fuel, modernisation of train components and integration of artificial intelligence (AI) and internet of things with the existing technology.
Innovations in rolling stock
The introduction of the Vande Bharat Express, in 2019, was a major feat achieved by IR in terms of indigenisation. However, with continuous upgrades over the years, IR has launched multiple variants of this train, including the Vande Bharat Express 2.0, 20-coach Vande Bharat Express and Vande Metro (Namo Bharat Rapid Rail). Further, the first prototype of the Vande Bharat Sleeper train has been rolled out for field trials by the Research Designs and Standards Organisation (RDSO) in December 2024, while the first look of the Vande Cargo was unveiled in September 2024. In addition to the Vande Bharat Express, the Amrit Bharat Express was launched in January 2024.
In line with the railways’ goal of achieving net zero carbon emissions by 2030, the final trial for India’s first hydrogen train will take place during January-March 2025. The design for this train has been completed and it will consist of eight passenger coaches, with the capacity to carry more than 2,600 passengers on a single journey, and three coaches for storing hydrogen cylinders. Recently, a toy model of this train was launched at the RDSO stadium in Lucknow in November 2024. Currently, Germany is the only country with operational hydrogen trains, running a two-coach model. The operationalisation of these indigenously developed hydrogen trains can create significant opportunities for India, in terms of first-mover advantage, further facilitating the country’s exports.
Domestic manufacturing of components
Amid disruptions in global supply chains due to recent geopolitical shocks, IR has adopted a proactive approach towards strengthening domestic capacity. Local sourcing of railway components plays a key role in building resilient domestic supply chains, ensuring smoother operations within the sector. Around 80 per cent of the components for Vande Bharat trains have been sourced from domestic suppliers. Further, with the aim of reducing import dependency on forged wheels (from Ukraine and China) while simultaneously boosting exports, IR acquired a forged wheel plant from Rashtriya Ispat Nigam Limited in Raebareli, Uttar Pradesh, for around Rs 23 billion. This initiative not only reduces India’s reliance on foreign technology but also enhances its manufacturing capabilities.
Domestic private players in the railways component manufacturing industry have stepped up to utilise this opportunity. For example, in September 2024, Jindal Stainless Limited provided IR with high-strength 301LN (low carbon, nitrogen alloyed) grade austenitic stainless steel to produce Vande Bharat Sleeper train coaches. Further, in July 2024, Vishvas Power Engineering Services Limited despatched a total of two 2×25 kV AC traction system transformers to IR. These are the first indigenously manufactured two-phase transformers that have been transported to the states of Bihar and Jharkhand.
With India being an ideal investment destination, offering lower interest rates and higher returns on investment, global players have also announced their plans to set up component manufacturing facilities. Alstom Holdings is planning to manufacture large batteries that can power Vande Bharat and Vande Metro train services for railway traction parts in India by 2025. Initially, the batteries will be imported from France, but the company aims to manufacture indigenous cells in India gradually. Meanwhile, CJSC Transmashholding is planning to develop several facilities for train and component manufacturing in India to meet their domestic requirements.
Integrated rail technologies
The advancements in IR’s fleet and components have given a boost to technology adoption in the sector. With newer and faster trains getting launched, their safety has become paramount. IR is currently in the process of upgrading the indigenously developed automatic train protection system Kavach, from Kavach 3.2 to Kavach 4.0, in their existing fleet. The newer variants, such as Vande Sleeper and Vande Metro, will be launched with the upgraded Kavach version. In December 2024, IR announced plans to implement an integrated track monitoring system (ITMS) across all its railway zones, at an investment of approximately Rs 1.8 billion, to enhance track safety. The ITMS features contactless track monitoring through laser sensors, high-speed cameras, light detecting and ranging technology, and other advanced tools.
IR has also implemented a live monitoring system in the northern part of West Bengal to increase train safety and prevent accidents. Further, in line with this system, it has also launched helmet cameras. These cameras will help in recording and monitoring the train’s parts, such as wheels and bearings, that are in motion.
IR is working on developing AI-based robots for monitoring its railway tracks, to ensure the safety and better operation of trains. These robots will be able to detect track issues such as rail cracks, water on tracks, petrol clips and fishplates, etc., and can further report real-time data of the same to the railway staff. Further, in June 2024, IR awarded a contract to Sensonic IN India Private Limited for the deployment of an advanced elephant detection system, also known as the Gajraj system, on East Coast Railway (ECoR) routes.
Increase in collaborations
In recent years, the railway sector has seen an increase in partnerships between private players and IR. This is expected to foster innovation and positively impact the sector’s net exports. A key example is Taural India Private Limited partnering with IR to provide aluminium casting solutions for the Amrit Bharat Express train. The aluminium gear cases manufactured by the company led to the replacement of imported aluminium casting elements from Germany. Further, Uniproducts India Limited has collaborated with the Integral Coach Factory (ICF), Chennai, to provide sound and thermal insulation materials for the Vande Bharat Express project. Furthermore, Wabtec Locomotive Private Limited, a joint venture between IR and the Wabtec Corporation, will manufacture the Evolution Series ES43ACmi Locomotive in Bihar’s Marhowra plant and export the same to Africa by 2025.
Further, the consortium of Ramkrishna Forgings Limited and Titagarh Rail Systems Limited is likely to start the manufacturing of forged wheels for Vande Bharat trains by July 2025. The facility will have a total annual production capacity of 250,000 units, which includes 80,000 to be used in India and the rest for export.
Strategic vision
The indigenisation of IR is crucial for achieving cost effectiveness, since locally manufactured components reduce procurement and maintenance costs. Moreover, the push for local manufacturing will lead to innovation and skill development through research, development and training within the railway sector. In line with this, the sector is placing significant emphasis on high-speed rail initiatives. IR has commenced manufacturing its indigenous bullet train, which is being developed on the Vande Bharat platform. The ICF at Chennai is responsible for developing the train’s design.
With the development a more futuristic approach and advanced technology, private players in India are experimenting with hyperloop technology. TuTr Hyperloop Private Limited, in partnership with the Chennai Unified Metropolitan Transport Authority, has completed the construction of India’s first Hyperloop test track, stretching 410 metres. In December 2024, TuTr Hyperloop successfully conducted initial trials of the technology at a speed of 100-150 km per hour. The project is located at the discovery campus of IIT Madras in Thaiyur, Chennai.
The shift towards self-reliance in the railways aligns with the broader goal of “Atmanirbhar Bharat”, which was highlighted by the Indian government to bolster the domestic economy, generate employment and enhance technological capabilities.
