Retrofitting old trains: Transforming diesel-heavy models into sustainable ones

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  Quantumrun Foresight
• December 1, 2021

In the past, trains were limited by manual operation and high fuel consumption, but retrofitting is transforming the rail transit landscape. By integrating advanced technology, retrofitting enhances train efficiency, extends their lifespan, and helps meet emission regulations. However, this shift towards more technologically advanced trains also presents challenges, including potential job losses in traditional rail industries and increased pressure on the power grid.

Retrofitting old trains context

Before the Internet of Things (IoT) and contemporary engineering standards, trains were constructed with a host of limitations. These early models were typically operated manually, a process that required significant human intervention and was prone to human error. Additionally, they were powered by outdated machinery that not only consumed fuel at a high rate but also produced high emissions. This combination of high fuel costs and elevated emissions presented a significant challenge to both the economic efficiency and environmental sustainability of rail transit.

However, the landscape of rail transit is undergoing a transformation, thanks to the efforts of retrofitting companies, such as US-based Progress Rail and UK-based Eminox. These firms offer rail transit organizations the opportunity to upgrade their existing train fleets, enhancing their capabilities and efficiency. The process of retrofitting involves integrating advanced technology into the existing machinery, making the trains smarter and faster. These adjustments not only improves the performance of the trains but also extends their lifespan.

The benefits of retrofitting extend beyond performance enhancement and cost efficiency. Retrofitting also enables these trains to comply with stringent emission regulations. Moreover, the integration of IoT technology results in a connected control system, which allows for real-time monitoring and control of train operations. This development not only improves the safety and reliability of rail transit but also enhances the passenger experience.

Disruptive impact

The transition from traditional fuel-powered trains to electric ones presents a significant challenge for the railway industry. Unlike cars and buses, which are smaller and more straightforward to convert, powering an entire railroad network with electricity requires a substantial amount of energy. The UK's Department for Transport has set an ambitious goal to electrify all public transportation by 2040, but the path to achieving this goal is still uncertain. Retrofitting companies believe that modernizing existing rail fleets is a crucial step in this transition.

An example of an upgrade is the installation of microprocessor technologies, which are commonly found in newer models. These technologies enable features such as telematics, which involves GPS monitoring, and remote diagnostics. These features allow for real-time tracking and maintenance of the trains. Another significant upgrade is in the emissions control systems, where a catalyst or chemical reaction is used to trap harmful gases like carbon dioxide. 

Retrofitting also presents a cost-effective solution for rail transit operators. Instead of completely replacing their old trains, which can be prohibitively expensive, operators can upgrade their existing fleets through retrofitting. Moreover, retrofitting can also help operators meet their sustainability goals, as demonstrated by Eminox's successful pilot in 2019, where they were able to reduce emission levels by 90 percent. This feat shows that retrofitting is not just a temporary solution but a viable long-term strategy for the modernization of rail transit.

Implications of retrofitting old trains

Wider implications of retrofitting old trains may include:

• Longer lifespan for old trains as train fleets would break down less often and repairs can be made proactively.


• A growing adoption by the public of multimodal transportation as train fleets can be increasingly integrated with modern transit management apps and systems.


• More people using rail for long-distance transit as a green and reliable mode of transportation.


• More railway companies maintaining a hybrid fleet of retrofitted and newer trains.


• Increased demand for interconnected vehicle control management technologies.


• The cost savings from retrofitting, as opposed to replacing entire fleets, allowing for lower ticket prices, making train travel more accessible to a broader demographic.


• The integration of IoT technology in trains leading to the development of smart cities, where data from various sources is used to improve urban planning and management.


• Job losses in traditional rail industries, requiring retraining and reskilling initiatives.


• Pressure on the power grid requiring significant investments in infrastructure and renewable energy sources.

Questions to consider

• What do you think are the other benefits of retrofitting trains instead of sending them directly to junkyards?


• How else do you think railway technology would evolve?