(Plasser & Theurer: Linz, Austria) -- Plasser & Theurer is a global technology leader for track maintenance machines. A globally active, family-owned company, it’s committed to supplying suitable track and maintenance systems to all regions of the world.

Although the basic operating principles are similar, specific requirements vary considerably from country to country. Plasser & Theurer will achieve this goal with reliable and precise machines, including an M30-G MILLTURN with automation cell.

M30-G MILLTURN with automation cell

Plasser & Theurer and WFL are two full-service providers united in their commitment to producing durable machines. The decision to invest in a MILLTURN with automation was undoubtedly influenced by these and other considerations.

Clemens Huber, plant planning and procurement, Plasser & Theurer, says, “We drew up a specification beforehand and invited tenders from five companies. WFL was the only company that met our requirements for accuracy and cycle time. We also expected very good support, as we are only a few minutes’ drive from each other.

“Achieving surface accuracy and concentricity of two different axes in relation to each other was vital,” Huber says. “We guarantee a maximum concentricity deviation of the cylinder to the central axis over both centers of less than or equal to 0.015 mm. The accuracy value is of the utmost importance here. Apart from WFL, no one could give us a 100% guarantee.”

Plasser & Theurer was determined to avoid interface problems. As a full-service provider, WFL supplied the in-house automation and integrated an external measuring machine and cleaning station. “The fact that everything is supplied from a single source was another decisive factor for us. WFL’s complete acceptance accelerated the ramp-up,” Huber says.

Lead time drastically reduced

The M30-G MILLTURN replaced four other machines. Before the investment, the production process was fragmented. Separate machines for sawing, milling, turning, and grinding were available at the main plant in Linz. All processing steps are now combined on one machine. The processing time has remained the same as the machines run in parallel, and the throughput time has been drastically reduced.

Raw parts can now be produced in less than 30 minutes. Before the MILLTURN was purchased, it took a whole day. This is a major advantage in terms of spare parts availability. The throughput time is minimized, and the setup time is reduced. The M30-G MILLTURN is the tool for producing a family of products where all the tools are always in the WFL machine.

MILLTURN in operation

Huber says, “The WFL machine was the first to be designed for a lightly manned shift. It’s possible for one operator to work on two or three machines at the same time because the WFL is so well automated. It’s clear that the more you automate these days, the better.”

The automation cell makes working on the machine much more pleasant for the operator.

The jointed-arm robot makes handling much more comfortable. The 15–25 kg raw parts no longer have to be transported by hand. The operator’s sole responsibility is now process and quality monitoring at the machine. “The operator’s workload has been reduced, as has our quality assurance, because every part is measured in the measuring station and declared as good or scrap,” says Huber.

EuProGigant as a flagship project

The EuProGigant project was launched at the same time as the final negotiations with Plasser & Theurer. WFL invested heavily in time, energy, and measurement data. This was, and still is, an important topic for the track construction company in terms of green footprint and sustainability. This quickly led to cooperation between WFL, Plasser & Theurer, and the Vienna University of Technology.

The WFL machine from Plasser & Theurer works in shifts, so it can provide meaningful measurement data. To summarize: WFL provides the technology and support, and Plasser & Theurer carries out the field test. The resulting energy data are findings that represent a win-win situation for everyone and generate considerable added value.

Service support is guaranteed.

WFL is a service partner of Plasser & Theurer, and quickly accessible due to its close proximity. Huber says, “We have had a very positive experience with WFL’s service. The response time is very short, and even WFL employees who aren’t actually in the field come to us when things have to be done quickly.” Huber also praises the smooth communication between the various departments at Plasser & Theurer and WFL.

Second-hand machine

The second WFL machine in the main plant in Linz is a completely overhauled M65 MILLTURN. “It’s a great sustainable alternative, and it’s also cost-effective,” Huber says. A new machine wouldn’t have been economical for Plasser & Theurer, because the machine is in two-shift operation at most.

A refurbished M65 MILLTURN can also be found at Plasser & Theurer's main plant in Linz.

“Buying used machines that look like new and come with a warranty is a great opportunity,” Huber says. “We are very satisfied with our purchase and are currently considering buying a second used machine from WFL.”

Sustainable into the future

Plasser & Theurer’s approach is clear: Ecology and economy go hand in hand. A few years ago, hybrid drive technology for machines was still the exception.

Today, the E³ generation of track-laying machines uses electrical energy from the catenary and battery power for the working drive. This reduces local emissions—pollutants and noise—on the construction site to virtually zero.

10 years of track maintenance machines with alternative drives from Plasser & Theurer—ecologically future-proof, powerful, and economically viable.

Demand for these machines is growing massively, and sustainability is now essential. “Our product lifetime of 30 years on average and a ‘lifetime’ spare parts guarantee make an important contribution to sustainable use,” Huber says. “Key issues for a production company like ours are resource recovery, energy consumption during processes and transport, and the emission of air pollutants.”

Plasser & Theurer is committed to minimizing these effects through targeted measures. It is certified according to ISO 14001 Environmental Management and ISO 50001 Energy Management. These certifications underline its efforts in the areas of energy efficiency, environmental management, and recycling management.