Astana Plant Producing Electric Locomotives

Located in Astana’s Industrial Park, the Electric Locomotive Assembly Plant has become a unique enterprise that not only manufactures railway locomotives but has also established local production of their key components. Designed for international markets, the plant’s products are manufactured using domestic raw materials and locally produced components, expanding the plant’s export potential. Ahead of Mechanical Engineering Day, we visited the enterprise and learned more about its production process.

From the first steps across the plant’s premises, the scale of production becomes apparent. Metal parts are processed in one workshop, while transformers are assembled in another area. The complex systems of an electric locomotive are then brought together into a single structure. Here, every component has its designated place, and every operation is carried out with precision. The plant has a designed production capacity of up to 100 electric locomotive sections per year. It manufactures KZ8A freight locomotives, KZ4AT passenger locomotives, onboard transformers and traction converters. To date, more than 450 electric locomotives have been produced for Kazakhstan and regional markets.

Another distinctive feature of the plant is its production of locomotives adapted to the railway standards used across the CIS. Railway gauges in Europe and China differ from those used in CIS countries. The Astana plant manufactures equipment compatible with the railway infrastructure of CIS countries. Therefore, when supplying products to these markets, not only technical compatibility but also geographical proximity plays an important role.

According to the plant’s Project Director, Beibit Ibrayev, the enterprise is currently using around 70% of its production capacity. Its products are in demand both domestically and abroad. Between 2018 and 2022, the company exported 40 electric locomotives to Azerbaijan. This year, 10 locomotive bodies were shipped to France.

“One of the key features of our production is that we do not simply assemble electric locomotives; we also manufacture their main components here. The production, cutting and processing of metal parts are carried out in close cooperation with domestic enterprises. Currently, more than 240 Kazakhstani companies are involved in our production chain. This helps develop local manufacturing and reduce production costs,” B. Ibrayev said.

The availability of the necessary metal raw materials in Kazakhstan also provides advantages for the enterprise. Processing raw materials and manufacturing finished components locally helps reduce transportation costs and lower production costs. At the same time, the high cost of similar components in Europe increases the competitiveness of production in Astana. The shipment of 10 locomotive bodies to France is one example. This order demonstrates not only that the plant’s products meet international requirements but also that they are competitively priced for foreign customers.

Looking ahead, the enterprise plans to participate in a tender announced by Georgian Railways. If the project is implemented, the potential order could amount to 45 locomotives, or 90 sections, to be delivered over several years.

Behind export deliveries is the work of the people directly involved in production. Production Manager Fildar Khassenov notes that operations at the plant are organized in two shifts.

“Conditions have been created to ensure stable working conditions for our employees. We provide transportation by dedicated buses and hot meals. A medical insurance programme is also available. We pay particular attention to young specialists. We cooperate with colleges and universities and accept students for internships. Young people who perform well in production may subsequently have an opportunity to join the company,” F. Khassenov said.

More than 750 people work at the plant. Every specialist — from electrical installers and mechanical assemblers to engineers — has a specific role in the production process. Workshop Head Uskenbai Alban graduated with a degree in Radio Electronics and Telecommunications. Today, he is responsible for the radio-technical equipment of electric locomotives and the production of cable products. He supervises a team of around 45 employees.

“Some of the required components are supplied by domestic enterprises. It can be said that the share of Kazakhstani components currently used in our production reaches 50%. As local manufacturing develops, our dependence on imported components decreases. This contributes both to the stable operation of the plant and to the development of domestic enterprises,” U. Alban noted.

One of the plant’s production areas is transformer assembly. This section is staffed by mechanical assembler Askar Kassymov. Having graduated in Electrical Engineering in Temirtau, the specialist has worked at the enterprise for more than three years.

“My main responsibility is assembling transformers. The quality of every component is extremely important here, as each one eventually becomes part of the overall electric locomotive system. That is why we pay particular attention to precision in our work. We operate in two shifts, and the company also provides social support to its employees,” A. Kassymov said.

The plant’s specialists also have opportunities to exchange experience with international colleagues. Employees travel to France to familiarize themselves with production processes. Further trips to other countries are planned as part of future knowledge and experience exchanges.

The production capabilities of Astana in the CIS market are directly linked to the specific characteristics of the region’s railway infrastructure. The availability of locomotives compatible with the railway systems of CIS countries offers consumers advantages both in terms of technical compatibility and supply logistics. This is complemented by Kazakhstan’s raw material resources. The metal required for electric locomotive production is available domestically. Processing it and manufacturing components locally, followed by supplying finished products to nearby markets, makes it possible to optimize production and logistics costs.

More than 240 domestic enterprises play an important role in this production chain. Some produce metal, others process it, while others manufacture specific components. Thus, electric locomotive production is not the result of the work of a single plant, but of an entire system of industrial cooperation.

Partnership with Alstom opens up opportunities for the enterprise to enter international markets. Compliance with international standards further increases interest from foreign customers.

The fact that the plant’s production capacity is not yet being used to its full extent also points to its potential to enter new markets. The Georgian market, transformer exports and new orders could contribute to further increasing production volumes.

The plant’s distinctive feature is that it does not simply assemble electric locomotives. It manufactures components, processes domestic metal, trains specialists and adopts new technologies. Most importantly, all these processes are integrated into a single production chain.

The long journey of a railway begins with a precise movement at the plant. Behind that movement are Kazakhstani metal, the work of domestic enterprises, the expertise of engineers and the painstaking efforts of production workers.

Source: https://egemen.kz/news/elektrovoz-qurastyratyn-elordalyq-zauyt