MAG IAS Secures Major Contract for Automated Railway Wheel Production Line in India

FFG subsidiary MAG IAS GmbH (MAG) has secured a significant contract to provide a highly automated production line for forged railway wheels to Ramkrishna Titagarh Rail Wheels Ltd (RKTR) in India. The multi-million-euro project aligns with India’s ‘Make in India’ initiative, which aims to transform the country into a globally competitive industrial hub by promoting local manufacturing and technological advancement.

This turnkey solution encompasses advanced machining and testing lines for the production of railway wheels, incorporating equipment from MAG and the HESSAPP brands. The system, set to be installed at RKTR’s Chennai facility, is designed to produce 100,000 railway wheels annually. Remarkably, the system can manufacture six different types of railway wheels without requiring a changeover, ensuring flexibility and efficiency.

One of the standout features of the system is its scalability—its design allows production capacity to be doubled if future demand requires it. To streamline the planning process and ensure rapid commissioning, FFG developed a digital twin of the system, accompanied by 3D simulations. The system’s energy consumption is carefully pre-calculated for various production scenarios, supporting sustainable manufacturing practices and optimizing the overall efficiency of the operation.

The system will incorporate cutting-edge technology, including MAG SPECHT 800 HMCs and HESSAPP VDM 1600 vertical lathes. It will also feature comprehensive coolant and chip management across the entire plant, as well as automation for both the machining and testing cells, measuring machines, a balancing station, ultrasonic testing units, and two magnetic particle inspection stations. These technologies will ensure the highest standards of quality throughout the production process.

A key feature of the production system is its centralized monitoring system, which enables real-time tracking of components and precise quality control, ensuring that each manufactured wheel meets rigorous standards.

Shashank MP, Managing Director of MAG IAS India Ltd, expressed confidence in the project’s success, stating: “The combination of cutting-edge German technology and local production in India will allow RKTR to meet the demands of the Indian railway sector while adhering to international standards. FFG’s expertise in turnkey manufacturing systems for railway wheel machining is recognized globally, with several successful projects already in operation.”

FFG CEO, Dr. Sebastian Schöning, added: “This contract win reflects our technological excellence and long-standing presence in India through FFG India. The close collaboration between our teams in Germany and India, coupled with our expertise in turnkey solutions, has given RKTR the confidence to choose us as their partner.”

Production is scheduled to commence in Q1 2026, with the system set to manufacture and deliver 1.54 million railway wheels to Indian Railways over the next 20 years. This major project not only supports India’s expanding infrastructure but also strengthens FFG’s foothold in the region.