The most significant, large-scale and high-profile project on the Central Asian railway market in recent years is the current launch of production of passenger coaches by Stadler Rail in Astana. The contract, valued at €2.3 bln and including the transfer of a plant, was secured after fierce competition with Russia’s TMH. In an exclusive article for the ROLLINGSTOCK almanac, published for the TransLogistica Kazakhstan exhibition, Stadler Kazakhstan’s CEO Vladimir Rusak discusses preparations for production, the modernisation of the site, the design of the coaches, localisation of manufacturing and future plans.
Published in the almanac “Rolling Stock Market. Kazakhstan” for the TransLogistica Kazakhstan transport and logistics exhibition
At the end of 2022, we signed a contract for the production and maintenance of 557 custom-designed passenger coaches with Passenger Transportation, a subsidiary of the national operator Kazakhstan Temir Zholy (KTZ). To implement the project, a plant was acquired in Astana. Originally, the plant was designed and built to produce coaches with dimensions not suitable for the 1,520 mm gauge area. Its equipment was outdated and did not meet Stadler’s standards. Moreover, it is important to understand that by the time the plant was acquired, more than 10 years had passed since its construction. Therefore, the infrastructure and equipment required extensive reconstruction and modernisation.
Vladimir Rusak, CEO of Stadler Kazakhstan
Against this backdrop, it was decided to significantly expand and modernise the plant to ensure efficient execution of current and future orders with Swiss-quality standards. Over KZT 5 bln (€8 mln) were invested in the plant’s reconstruction. The funds were allocated for purchasing modern equipment, constructing new workshops and warehouses, carrying out overhaul of production buildings.
By the end of 2024, we completed all key stages of the reconstruction. Driveways, access roads, crane and transfer platform shelters were built and expanded; railway tracks were renovated; and inspection pits were arranged. A full reconstruction of the welding and painting workshops was carried out. Warehouse space was increased to 11,000 m2, and the roofing, flooring, and lighting systems were upgraded. The fire extinguishing system was completely modernised, and the plant’s entire power supply system was replaced. Reconstruction is still ongoing: the launch workshop for coach maintenance is being expanded, and the administrative building and main facility are undergoing renovation.
The product for KTZ is custom, and its development began long before the start of production. While the plant was undergoing reconstruction, engineers from the Stadler Group were already working on designing the coaches according to the client’s requirements. Stadler traditionally develops its engineering divisions based on specialisation rather than geographical location, which enables experts from different engineering centres within the group to collaborate on a single project. This approach allowed us to optimise the project timeline and begin production immediately after completing the main phase of the plant’s reconstruction in Astana.
At the same time, we engaged specialists from other Stadler plants to establish production processes, while Kazakhstani employees were sent for training in Poland, Spain, Switzerland, and Belarus. Colleagues from other divisions brought their expertise to Kazakhstan. Their practical experience working according to Stadler’s quality standards, along with their proficiency in both English and Russian, significantly simplified communication with local specialists and official representatives.
Installation of electrical systems in a coach at the Stadler plant in Astana. Source: Stadler Rail
During the development of technical solutions and interior design, all client preferences and requirements were taken into account. As the contractor, we provide recommendations based solely on our international experience. The local coaches from Stadler designed with consideration of Kazakhstan’s climate and the route lengths. They are built to operate in temperatures ranging from -50 ºC to +45 ºC.
The design includes:
-
- enhanced thermal insulation of the coach body,
- high-capacity heating and air conditioning systems,
- pre-start heating for diesel engines,
- cyclone filters to protect against sand and dust,
- special air intake grilles to prevent snow ingress.
The bogies for Stadler coaches also feature a different frame and beam design adapted for the 1,520 mm gauge. They are made from special steel resistant to extreme temperatures.
Currently, certification of coaches for compliance with TR CU 001/2011 is actively underway. Initial test runs on the infrastructure of the Republic of Kazakhstan have been carried out as part of the certification trials.
Bogie of the passenger coach by Stadler for Kazakhstan. Source: Stadler Rail
As of today, the full cycle of technological operations — from welding and painting steel bodies to installing pneumatic and electrical systems — is localised and carried out at the production site of Stadler Kazakhstan in Astana. The only exception is the welding and painting of aluminium bodies, which is temporarily performed at other Stadler Group facilities. This is due to the organisation of the Stadler Group, within which the main components, such as aluminium bodies, are manufactured at specialised centres of competence. These centres supply components to other Stadler production plants, ensuring the standardised and highest-quality Stadler vehicles worldwide.
Each coach includes over seven hundred types of components supplied by 18 Kazakhstani companies, and this number continues to grow. We are ready to purchase any components that meet Stadler’s standards from Kazakhstani manufacturers. This also results from our strategy: each of our plants develops a chain of local suppliers based on geographical proximity not only to improve logistical efficiency, but also to better understand local specifications and customer requirements.
In a Stadler passenger coach compartment for Kazakhstan. Source: Stadler Rail
We plan to increase our investment in Kazakhstan and transfer more production processes to the local site. This will raise the level of localisation and integrate the Kazakhstani cluster into Stadler’s global supply chain.
The contract with Passenger Transportation includes both production and technical maintenance of the coaches for 20 years. Joint work is currently underway to build depots in Astana and Almaty.
Stadler products are available worldwide, and we already operate in the passenger coach segment in Europe. We are open both to domestic orders and cooperation with neighbouring countries. Stadler is known for its personalised approach to each customer, and we are ready to bring this tradition to Central Asian countries.
Author: Vladimir Rusak, Chief Executive Officer of Stadler Kazakhstan
