Innovations in Rail Freight

22 February 2023, Doncaster

Conference delegates hear how innovation in rail freight can support growth, improve sustainability and increase productivity, reducing carbon emissions from long-haul freight and improving biodiversity along the way.

Rail Freight was the topic for discussion at the latest Unlocking Innovation event, organised by the Railway Industry Association (RIA) and hosted by Unipart Rail at its Doncaster offices, as around 130 delegates representing 100 different organisations gathered at Unipart’s Technology and Innovation Hub, which it has developed in partnership with the UK Rail Research and Innovation Network (UKRRIN).

For more than a decade, RIA’s Unlocking Innovation events have showcased new ideas and thinking from across the industry, reaching thousands of people and making the case for the sector as a leading light for innovation. The programme has two clear aims – to promote the many innovations and developments within the UK rail industry and to connect businesses together to open up new opportunities to innovate. Doncaster deputy mayor Glyn Jones welcomed delegates to the city.

Doncaster has a long and proud railway history, he said, and rail freight has played a large part in that history. Today, the city is home to a number of rail-industry companies and organisations that are receiving national funding to develop innovation and technology, boosting prosperity and employment both locally and throughout South Yorkshire. 

Unipart Rail’s managing director Neil McNicholas told the audience that innovation in UK rail freight was close to his heart. As a former managing director at Freightliner, he was looking to innovation to reduce cost, enhance operational efficiency and improve sustainability in the sector.

 

Keynotes

RIA innovation director Milda Manomaityte then introduced the first of the event’s keynote speakers – Rail Freight Group director general Maggie Simpson. Having highlighted rail freight’s importance to the UK economy, removing the need for 7.6 million lorry journeys every year, she bemoaned the fact that the industry was still using methods that would have been familiar to Brunel, “or at least to his children”. Rail freight is crying out for “new systems and technology”, she said.

Representing the railway’s future, Richard Moody of the Great British Railways Transition Team called freight “a private-sector success”. He was followed by two representatives of those private operators. Marie Banks of DB Cargo admitted that, as an industry, “we never have all the answers”, but called for new technology to be readily fitted to existing rolling stock assets, which have a lifespan in excess of 20 years.  GB Railfreight’s Tim Hartley talked of new technology that is being introduced, including the company’s new Class 99 bi-mode locomotives that will start arriving next year and will bring environmental as well as performance benefits.

Lucy Hudson of Transport for the North promoted the idea of using wagons that can be loaded with a complete HGV trailer rather than just a container, speeding loading and unloading and making rail freight even more cost effective. She also called for interventions to improve both the rail and ‘last-mile’ road networks to speed up freight flows.

RSSB (Rail Safety and Standards Board) was represented by two speakers. Research and innovation account manager Robert Staunton outlined how current research programmes funded by the Department for Transport (DfT) aim to unlock new opportunities by allowing new ways of working and “clearing a path for industry to follow”. His colleague Aaron Barrett introduced delegates to the Rail Technical Strategy for CP7 (Control Period 7 – 2024 to 2029) which aims to improve capabilities, develop new terminal sites, technologies and processes to reduce turn-around times, prioritise freight and increase average and maximum speeds.

The Freight Innovation Fund, a £7 million programme funded by the DfT and delivered by the Connected Places Catapult, was described by SME innovation funding team leader Giulia Lorenzini. This multi-faceted programme will focus on accelerating the adoption of multi-modal, commercially ready solutions into the sector. It will support SMEs and fund trials through the Accelerator Programme and Freight Innovation Cluster. The cluster programme will run throughout the programme while the accelerator programme will identify and fund up to 36 SMEs over three cohorts until 2024.


 

Innovation Showcases


The afternoon sessions showcased innovations from industry. Sam Gilbert of Eversholt and Phil Read of Varamis Rail explained how a Class 321 passenger train have been converted into an express freight carrier, primarily aimed at the express parcels and online shopping markets. Five four-car units have been converted so far and trials have been undertaken to establish the best and quickest way to load and unload trains at main line stations. Varamis Rail is currently operating one unit between Glasgow and Birmingham five nights each week, and there are plans to extend this to London during 2023.

Operating a train capable of 100mph allows freight services to run between passenger services without the risk of delaying them, making timetabling much easier. A fully loaded four-car train is far more cost effective than operating the four articulated lorries it replaces, particularly as it can run straight into city-centre stations and rail-connected depots without encountering delays from a congested road network, and Phil urged parcel carriers to avail themselves of the service.  “Use it or lose it,” he told them.

Ian Johnston, head of engineering at D-Gauge, introduced delegates to some of the intricacies and pitfalls of gauging. He explained that, while in theory a train carrying containers on flatbed wagons needs a line to be cleared to the W12 gauge, which lines in many parts of the country currently are not, using a common FEA-C wagon with a 2.5 metre (9ft 6in) container can open up many more routes to container traffic. He therefore proposed that Network Rail should clear routes for specific wagon types rather than the “one size fits all” W gauge classifications.

Another piece of fresh thinking was detailed by Simon Evans of Wabtec and Tim Danvers of Atkins. The Self-Powered Bogie Project proposes to fit freight wagon axles with traction motors and energy recovery systems. Electrical energy generated while braking the train can be stored on board, and then used to assist the train when starting from rest or climbing steep gradients. This approach will reduce carbon emissions, energy consumption and operating costs.

A new traction motor is currently being designed and prototypes will be available towards the end of next year.  Trials will then run until 2025 after which the system will go into production.

Knorr-Bremse, although a German company, has its Centre of Excellence for Brake Control in the UK. The company is working to solve some of the rail freight industry’s problems through improved monitoring and data analysis. Features such as derailment detection, axle lock and wheel slide prevention, location monitoring and wheel profile checking are all included in the programme.

Instrumental is a company in the Unipart Rail group. Sam Bussey described how it is also working on data monitoring by developing ‘Paradigm Insight’, which uses ruggedised sensors to record data on a train’s systems and performance, allowing potential failures to be identified and then corrected during routine maintenance rather than waiting for a costly failure to occur.

To complete the presentations, Steve Freeman and Paul Bathgate described the facilities now available at Doncaster’s iPort inland terminal and how initiatives such as the RailX freight booking system can increase the utilisation of intermodal freight trains, currently running at about 75 per cent, by allowing hauliers to book loads onto otherwise empty wagons at short notice.

The event then closed and, following a few final remarks from Milda and a plug for RIA’s Innovation Conference, being held at Nottingham on 28/29 March, delegates boarded a coach for a tour of the iPort facility.

 

iPort Rail Tour