Innovations at iaf 2025: Plasser & Theurer presents the future of railway technology

The International Exhibition of Track Technology (iaf) in Münster is considered the leading trade fair for the railway construction industry and will take place from 20 to 22 May 2025. Ahead of this important event, we had the opportunity to talk to Johann Dumser, Global Director Marketing & Communication at Plasser & Theurer. As a leading supplier of railway maintenance machines, the company uses the iaf as a central platform to present its latest innovations. Johann Dumser provides insights into the importance of the iaf for the industry, the innovations that Plasser & Theurer will present at the trade fair, as well as the current challenges and future strategies in the rail sector. From autonomous tamping machines to sustainable technologies, Mr Dumser provides insights into the future of rail infrastructure and the role played by the international trade fair in this.

Mr Dumser, Plasser & Theurer is a renowned company in the field of railway construction machines. Could you start by giving us a brief overview of your company?

Johann Dumser: Gladly. Plasser & Theurer, founded in Austria in 1953 by Franz Plasser and Dr Josef Theurer, is now a leading exporter of railway construction machines. We generate a turnover of around 500 million euros in Austria and are one of the country's leading companies. With an export share of 95 per cent and the motto ‘We believe in railways’, we are a third-generation family-run business. The first innovation was the development of a tamping unit with hydraulic drive in 1953, a technology that is used worldwide today. We currently employ 2,200 people in Austria and a total of 6,000 worldwide. Our machines have already been delivered to 110 countries – practically ‘everywhere’ there is a railway. With 22 partner companies in countries such as Germany, France, the USA, India, Australia and South Africa, we are represented worldwide.

That is impressive. Let's talk about the upcoming iaf trade fair. How important is this event for Plasser & Theurer?

Johann Dumser: The iaf is undoubtedly the most important trade fair for the entire track maintenance industry. It has existed for much longer than InnoTrans and has a strong international character. The trade fair brings together key decision-makers in Münster, including railways, construction companies and all other stakeholders in railway infrastructure. It is the most important platform for our industry, so important that some employees even take leave to be there – especially machine operators. Münster is the ideal venue for the event, as typical operational situations can be demonstrated live on 3,000 metres of ballasted track. The company stands inside the iaf supplement the service portfolio for track maintenance, for example, through engineering and planning offices. The latest innovations and techniques can be presented in a concentrated area. In addition, the seminars and the iaf Salon offer platforms for high-level professional exchange and international networking.

What innovations will you be presenting at the iaf?

Johann Dumser: We will be presenting our latest developments in the field of autonomous tamping, as well as further developments in rail welding, for example. In addition, we will be presenting our expanded customer services.

One of the key topics will be our sustainable technologies in the E³ series. Plasser & Theurer has been committed to sustainability in product development for many years. Today, we are the leading provider of a comprehensive range of sustainable technologies with measurable, long-term benefits for railways and the environment. For example, our innovations enable 40 per cent lower fuel consumption with the Eco Retrofit and 80 per cent CO2 savings

That sounds like significant progress. What challenges do you currently see for your industry, particularly in Europe?

Johann Dumser: In Europe, the increasingly strict regulations, standardisations and approval conditions for special vehicles, which include our railway construction machines, represent a challenge. These processes are often time-consuming and personnel-intensive. It is important to understand that our equipment is not a means of transporting people or goods, but highly specialised machinery. For infrastructure managers, construction work always represents a cost factor, as they only make money from ‘rolling stock’. The availability of the track is the main focus for infrastructure managers. This means that track possessions for maintenance and servicing must be short. This requires highly efficient and specialised machines that are durable and designed with such a high level of technology that downtime can be reduced to a minimum.

The shortage of skilled workers is a cross-industry issue. How do you meet this challenge?

Johann Dumser: The shortage of skilled workers is indeed ubiquitous. We offer attractive working conditions, such as ergonomic cabins in our machines and quiet, low-emission hybrid drives. Nevertheless, working at unusual times – at night, on weekends and holidays – remains a challenge. We have a variety of solutions. We are developing automatic, AI-supported machines that reduce the need for personnel. Where three to four people were needed in the past, one or two people can be deployed today (depending on the respective regulations, of course).

In training, we rely on innovative methods such as full tamping simulators, comparable to flight simulators for pilots. This way, career changers can be effectively trained within six weeks.

Plasser & Theurer trains itself. What advantages do you see in this?

Johann Dumser: Our own training programme ensures that we have good junior staff and promotes long-term company loyalty. In the Franz Plasser Vermietung von Bahnbaumaschinen Ges.m.b.H, we have our own machines for use on the Austrian Federal Railways. We use the workplaces on these machines as a ‘training ground’ for track construction and for the professional operation and maintenance of our products. The satisfaction of our employees is very important to us. Many start their careers with us as apprentices and also retire here. The length of service of some employees corresponds to the lifespan of some track components - between 30 and even 50 years. But our machines are also in use for a very long time. When I started working for Plasser & Theurer in 1990, machines were used that are still in successful operation today, in 2024.

How do you optimise track construction sites and what are your priorities?

Johann Dumser: Although a completely CO2-free large construction site is not yet feasible, we are continuously working on environmentally friendly solutions. Our high-performance machines offer railways an economic advantage through extended maintenance cycles (for example, in the case of subsoil remediation). Where tamping used to be necessary every year, this is now only necessary after many years. An important aspect is the integration of various work steps in construction projects into one machine. Thanks to assembly line technology, only the construction track is used for work and material logistics. Optimisation of the operating technology and the operating concept for the machines reduces the time spent by machine personnel in the danger area.

How do you see the situation in Germany, a country with a traditional affinity for railways?

Johann Dumser: Germany has one of the largest and densest rail networks in Europe. German railway technology and the German railway industry enjoy a high international reputation. However, there is a need for action in terms of infrastructure and maintenance in order to reduce train delays and to increase the reliability of the system again. The current plans of DB InfraGo regarding the general overhaul and the maintenance containers are very welcome. Of course, long-term financing of the construction measures by the government and a plannable framework for the construction industry are important for implementation.

What could an effective five-year goal for the industry look like?

Johann Dumser: Many people have become loyal rail customers in recent years. We must not lose them again. Rail is not only an efficient and safe means of transport, but also promotes cultural exchange. As is well known, travelling broadens the mind.

Achieving the CO2 targets is also a focus and is massively supported by the railway system. At the EU level, we would like to see more sense of proportion in new laws with a focus on realistic and economic feasibility. For our customers, we would like to see more planning security with regard to the financing of construction and maintenance projects.

Finally, can you give a specific example of innovation and strategy in your company?

Johann Dumser: A prime example is our focus on the digitalisation of railway infrastructure. We develop digital machines that use sensors, AI and advanced measurement technology to analyse not only the track geometry but also obstacles and the condition of the ballast in real time. These machines automatically adjust the operating parameters accordingly, document the actual condition and thus provide the data basis for future measures. This enables predictive maintenance, which significantly improves resource and personnel planning. One of our latest innovations is a measurement and analysis method that monitors the properties of the ballast throughout the tamping process and displays the ballast condition in previously unattainable detail.

We also focus on efficiency and sustainability when tamping the ballast bed. With our dynamic track stabiliser, we achieve a more durable track position through spatial compaction. In doing so, we take into account that railway engineers have to plan very far into the future – often for periods of 30 years or more.

Mr Dumser, thank you very much for these detailed and expert insights into your company and the industry.

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