Bulgaria: The only locomotive manufacturer in the country specializing in small shunters is building a new workshop with an area of about 4,000 m2 for the development of overhaul competencies. The new facilities will have 3 access roads and should triple the production area of Express Service in the city of Ruse.
Express Service received its first overhaul experience in 2020-2022, fulfilling an order by the national BDZ operator to modernize two narrow-gauge 77 series diesel locomotives, which were produced in 1988 by FAUR (Romania). This was the first contract for the company to provide such services to BDZ. The scope of work included the replacement of a diesel engine (C32 Stage V by Caterpillar was installed), a driver’s cab, control panels, an air compressor, etc. According to Tsvetelin Kolev, Express Service manager for working with foreign clients, only the frame remained from the old locomotive.
The 77 series diesel locomotive before (left) and after (right) overhauling by Express Service. Source: BDZ, Express Service
Tests of the first repaired locomotive took place in April this year. It hauled a train of 3 passenger coaches and 1 diesel locomotive weighing about 100 t, which is equivalent to 6 passenger coaches, according to Express Service. After the trials, the company expected payment from BDZ and planned to start overhauling of the next locomotive, but the IAJA railway administration did not allow its operation and demanded the re-certification procedure for the locomotive due to too many changes.
Modernized 77 series diesel locomotive on trials in Bulgaria. Source: Express Service
It should be noted that these are not the first claims of IAJA to the work of the Express Service. Previously, the agency revoked the company’s business license, later this decision was canceled by a court decision. The revocation of the license was preceded by criticism of BDZ tenders by Express Service: the company was not allowed to participate in tenders for the repair of rolling stock, and representatives of the operator claimed that there are no facilities to repair locomotives in Bulgaria. This later led to the cancellation of several controversial tenders, but Express Service was excluded from the repair programs of BDZ until 2020. Nevertheless, this did not negatively affect the repair capacities utilization at the Express Service site. According to the Offnews local media, the company took over the maintenance of locomotives for almost all private operators in Bulgaria and Romania.
According to the Organization for Cooperation of Railways (OSJD), in 2020, the average daily operating fleet of BDZ was 155 locomotives (diesel locomotives – 53 units) in 2020. In 2019, the country’s authorities announced plans to modernize locomotives at a rate of up to 15 locomotives per year. Also, Smartron electric locomotives by Siemens Mobility were were purchased in 2021. In July this year, the Ministry of Transport, Information Technology and Communications of Bulgaria announced that a comprehensive tender for the rolling stock delivery would be launched in the near future. One of the lots involves the supply of 18 battery-powered shunting locomotives.
Express Service declared its interest in this tender as well: the Bulgarian manufacturer is known precisely for its competence in the battery shunters production. The company was founded in 1998 by Anastas Kolev, former deputy director of the Vasil Kolarov Locomotive Repair Plant. It all started as a small depot, where the locomotives of private operators were serviced. Gradually, the company expanded, in 2009 it built a production facility in the vicinity of Ruse and purchased equipment from the bankrupt Vasil Kolarov plant. Express Service currently employs around 200 people and generated 8.8 mln BGN (€4.5 mln) in revenue for 2020.
The production of locomotives was mastered in 2002 and began with diesel engines: now the Express Service portfolio includes three shunting diesel locomotives – MDD3, MDD4 and MDD5 – with a power range from 300 to 960 kW and a maximum tractive effort from 120 to 240 kN.
Two MDD3 diesel locomotives before sending to the Sofia Metro. Source: Express Service
ES1000 battery locomotive hauls a Hitachi Rail class 802 train at Harwich depot, UK. Source: Express Service
Express Service has been producing battery locomotives since 2005, and the range of small battery locomotives currently includes the two-axle ES600, ES1000 and three-axle ES3000. It is stated that, depending on the model, the vehicles can haul trains weighing from 600 to 3,000 t, their power range is 34-90 kW. Battery locomotives are currently the most demanded products of Express Service: the sales territory includes Bulgaria, Lithuania, Latvia, France, Great Britain, and India. A battery-powered locomotive prototype with higher power is currently under development. It is worth noting that since 2020, the company has been issuing “green” certificates to each customer of battery locomotives, which provide the opportunity to install solar panels to charge locomotives at the expense of Express Service.
