On track for expansion Bonatrans

ON TRACK FOR EXPANSION

Bonatrans is a global leader in the design and manufacture of wheelsets, wheels, axles and tyres for every type of railway vehicle. Philip Yorke reports on a company that has gone from strength to strength following its acquisition of GHH-Radsatz GmbH of Germany. Today new product development and innovative solutions are helping to drive the expansion of the group still further.

The GHH-Bonatrans Group was founded in its present form in January 2014, when the Czech based Bonatrans Group acquired the German company, GHH-Radsatz GmbH. Both companies have distinguished manufacturing traditions stretching back many decades and are leaders in their individual product sectors. Bonatrans is strong in high volume, heavy rail solutions, while GHH is the European leader in light rail applications.

The group continues to invest heavily in new product development and the latest technology which is paving the way for further global expansion. The group employs over 20,000 people worldwide and in 2015 recorded sales of more than €350 million.

Indian investment driving growth

Last year the GHH-Bonatrans Group completed the construction of a major manufacturing facility in India. This new state-of-the-art plant is already producing 20,000 wheels and 6000 axles per year, as well as assembling more than 5000 wheelsets per annum. The group is focussed on targeting the high-end markets in Asia, where there is fast-growing demand for more advanced products. The strategic goal for entering this market is the region’s need for safer and more efficient transportation of people and goods in the Indian sub-continent.

The GHH-Bonatrans Group’s success in these markets is assured thanks to the fact that in addition to the growing market in India for new rolling stock, many of its long-term customers are already active in this market including global OEM’s such as Alstrom, Bombardier, Siemens, GE and Hyundai Rotem.

However, the group is also pushing for expansion yet further afield in places like China where it has secured a number of significant light-rail projects. The production lines at the company’s state-of-the-art facilities in Aurangabad, India are equipped with cutting edge axle and wheel machining and coating technologies. They are also fully integrated for the complete assembly of wheelsets. This is in addition to mounting other components such as brake discs, bearing systems and running gear. The annual production for the new plant is 20,000 wheels, 5000 axles and over 5000 wheelsets.

Leading through innovation

Throughout its history, Bonatrans has always placed a high priority on R&D and innovation. The group today supplies a wide range of high-tech products and solutions, including resilient wheels, heavy rail wheelsets for high-speed locomotives, low floor solutions

including noise absorbing systems and advanced speed sensor and ground contact systems for non-driven independent wheel axles.

The advanced sensor technology and electric ground contact are mounted on the portal axle end. This construction, including its flange-mounted brake discs, uses far less space than other similar solutions. This extra space can be used for the installation of additional components such as hydraulic brake systems.

Another important new development at GHH-Bonatrans has been the introduction of its new, super-resilient wheel, the GHH-ULTRA-S series. These special wheels are designed for vehicles with 12.5 ton axle loads and meet all the regulatory requirements for a resilient wheel transport with a tread diameter of 600mm, in addition to securing very low radial stiffness of 20–40 kN/mm.

Bonatrans has also developed a unique family of dynamic noise absorbing systems called BONASILENCE. The latest example of these were recently supplied to the BVC company of Germany. The expected lifetime of this special damper system is over 15 years, and it can be designed to fit any wheel diameter.

BonaStar® is another innovative and unique Bonatrans product which is comprised of a family of new wheel materials designed to enhance all types of passenger, locomotive and freight wheelsets. In comparison to wheels made with standard EN Grades, BonaStar® offers a 30 per cent greater lifespan in mileage by significantly increasing the fatigue limit in the wheel web and by providing greater hardness and strength to the wheel rim.

Broad environmental programme

As a global exporter GHH-Bonatrans takes its responsibilities concerning the environment very seriously, not only with regard to environmental protection but also in relation to care for its local neighbourhood. Regular upgrades of production facilities and the implementation of new technologies has resulted in significant reduction of environmental impacts, prevention of potential accidents and emergency situations that affect both the environment and employee health.

The company’s ecological prevention programmes involve employee educational programmes and training as well as the monitoring and reduction of environmental contamination. GHHBonatrans also observes strict rules on waste management protocols with special waste containers in the workplace and a comprehensive waste management system. n

For further details of GHH-Bonatrans’ innovative products and services visit: www.ghh-bonatrans.com