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Author: Livia In-Albon

ETCS Level 2 rollout planning with integrated infrastructure, operations and rolling stock lifecycle coordination.

Planning the integrated rollout of ETCS Level 2

Customer: BLS Netz AG, Switzerland

Project tasks

  • Project management
  • Integrated rollout planning
  • Cost assessment
  • Stakeholder management
  • Long-term planning

Our approach

As part of the ERTMS strategy of the Federal Office of Transport (FOT), Swiss infrastructure operators developed a long-term implementation concept for the network-wide introduction of cab signalling based on the European Train Control System (ETCS) Level 2.

PROSE supported BLS Netz AG in finalising the integrated rollout plan. We reconciled the different requirements of long-distance, regional and freight transport companies regarding rolling stock with the operational needs of the infrastructure. In parallel, we took the life cycles of existing systems and their depreciation effects into account.

On this basis, we developed a consolidated best-case scenario that defines the section-by-section implementation and commissioning, while transparently outlining the resulting investment and depreciation effects.

PROSE supported BLS in project management during the final phase of the implementation concept. Based on the selected best option:

  • We refined the planning with the involvement of all stakeholders
  • Quantified the resulting costs and depreciation
  • Coordinated the final draft resolution internally and externally with the other infrastructure operators.

The implementation concept is based on an integrated consideration of the life cycles of rolling stock and infrastructure. At the same time, the various potential benefits of ERTMS were systematically taken into account. A key element was to ensure operationally manageable migration through coordinated, coherent implementation, with the clear aim of avoiding fragmented ETCS island solutions.

Customer benefit

BLS Netz AG benefited from our comprehensive understanding of the planning triangle of operations, infrastructure and rolling stock, as well as our in-depth expertise in the field of ERTMS. Our structured methodology and independent consulting services provided a robust, coordinated basis for decision-making. The implementation concept was completed on schedule and in close cooperation with the specialists and programme management. PROSE embodied technical clarity and independent expertise.

 

  

Intelligent rail head lubrication concept with data-driven monitoring, lubrication systems and rail analytics visualised on an urban track.

What comes next when intelligent rail head lubrication has been validated?

Our intelligent rail head lubrication research project has shown that intelligent, data-based rail head lubrication works under real operating conditions.

However, it has also become clear that questions remain regarding the stability of the effects across different routes, vehicles, and operating conditions. Further questions concern the interaction between rail head lubrication and wheel flange lubrication, as well as how data-driven systems can be scaled without adding complexity for operators.

The focus of the project is shifting from proving feasibility to optimising and expanding the knowledge gained:

  • Extending the system to additional routes and vehicle types
  • Integration of intelligent flange lubrication alongside rail head lubrication
  • Analysis of interactions between vehicles, infrastructure and operating conditions
  • Strengthening of monitoring, control logic and operational robustness

The goal is to move from isolated applications to scalable, operational solutions that support asset maintenance, cost efficiency and environmental performance throughout the entire life cycle. The project thus marks the transition from research results to a basis for long-term application.

Further information on objectives and scope can be found here: https://www.aramis.admin.ch/Default?DocumentID=74023&Load=true

Sustainability report – Digital ESG reporting with clear KPIs and transparent sustainability communication.

Sustainability Report – Progress made visible

Customer: Scheuchzer AG, Switzerland

Project tasks

  • Analysis and evaluation
  • Development of the report
  • Quality assurance
  • Project management and coordination of the creation process

Our approach

Scheuchzer AG needed to update its sustainability report for the 2024 financial year and present it in a clear, impact-oriented format. The objective was to consolidate ESG performance in 2024 into a clear and structured format and to communicate key figures, implemented measures and achieved progress in a transparent and comprehensible way.

PROSE supported the customer in developing and preparing the sustainability report for the 2024 financial year. The scope of work included the following key activities:

  • Analysis and evaluation of existing sustainability data and relevant internal documents
  • Development and editorial preparation of report content in close consultation with the customer’s specialist departments
  • Integration of measurable sustainability goals, concrete implementation measures and key performance indicators (KPIs) for monitoring success
  • Ensuring clear, consistent and target group-oriented communication strategy troughout the report
  • Coordination of the entire creation process, including scheduling and quality assurance, through to final approval and publication of the report

This approach ensured that the sustainability report met high professional standards and provided a reliable basis for Scheuchzer’s sustainability communication.

Customer benefit

The preparation of the 2024 sustainability report by PROSE provided clear added value for Scheuchzer. All ESG information was professionally structured, clearly formulated and consistently presented.

Based on our experience from comparable projects, PROSE identified gaps at an early stage, requested missing data in a targeted manner and translated complex ESG requirements  into clear and comprehensible content.

In parallel, we ensured that the results were presented in a way that addressed the needs of relevant internal and external stakeholders and supported consistent sustainability communication. Our independent, external perspective added credibility and objectivity to the report.

Overall, Scheuchzer received a sustainability report that was technically sound, communicatively strong and tailored to the requirements of both internal and external target groups.

 

 

Marco Pagani appointed Co-Director of PROSE Business Unit Switzerland, pictured with Lukas Müller, Rolf Mühlemann and Jochen Helmlinger, CEO.

Marco Pagani appointed Co-Director of PROSE Business Unit Switzerland

We are pleased to announce that Marco Pagani will take on the role of Co-Director of our Business Unit Switzerland as of 1 May 2026. Together with Lukas Müller, he will lead the continued development of our activities in Switzerland, working in close collaboration with customers, partners and colleagues.

Marco Pagani brings extensive experience in fleet strategy, asset management and large procurement programmes within the European railway sector. He has been responsible for international locomotive fleets and major investment projects and currently contributes to national ERTMS and high-speed train programmes in Switzerland. With technical, strategic and financial expertise, he has led international teams and delivered complex initiatives across the railway industry. This experience ensures continuity and strong leadership for the PROSE Business Unit in Switzerland.

After 11 years with PROSE, Rolf Mühlemann is moving on to pursue new opportunities. We thank him for his long-standing commitment and for the foundation he has helped build within the Business Unit.

With this transition, we remain committed to supporting our customers with independent expertise and reliable customised solutions within railway technology.

Please join us in welcoming Marco Pagani to his new role.

Intelligent rail head lubrication concept showing wheel-rail interaction, wear mechanisms and data-driven railway engineering.

Reducing noise and wear begins with understanding why they occur

The results from our research project show what intelligent rail head lubrication can achieve in practice. In order to turn observed effects into robust, transferable solutions, we need a deeper understanding of the mechanisms behind wear and noise in the wheel-rail system.

For this reason, a special literature study on wear mechanisms was an integral part of the intelligent rail head lubrication research project. The study summarises the current state of scientific knowledge on the following topics:

  • Rail waviness and slip waves
  • Wheel polygonisation
  • Friction-induced vibrations and resonances
  • The role of lubrication in various operating scenarios

A key finding: Waviness and polygonal wear do not have a single cause. They arise from the interaction of vehicle, track, operation and friction. This has direct implications for operators: measures that work in one context may have unintended consequences in another.

Targeted, data-driven lubrication must therefore be combined with an understanding at the system level.

The results of the literature study help to place rail head lubrication in a broader context and form an important bridge between research results and future application and scaling.

The full literature review can be found here (only in German): https://www.aramis.admin.ch/Dokument.aspx?DocumentID=73690

Expert presentation on intelligent rail head lubrication with digital rail technology visuals and PROSE branding.

Why intelligent rail head lubrication is not a niche topic

The results of our research clearly show that noise, wear and tear, and resource use can only be optimised together if decisions are made on the basis of data.

Many questions are currently arising among operators, which can only be addressed through open dialogue between operators, maintainers, researchers and technologists.

That is why we want to spread the topic of intelligent rail head lubrication into various specialist formats and share our knowledge. Two events in the coming weeks will provide an important platform for this, offering different perspectives:

On 5 March 2026 in Dresden, Dr Felix Saur, our expert in wheel–rail interaction, will speak at the 21st International Railway Vehicle Conference on Self-learning rail head lubrication for trams

On 11 March 2026 in Vienna, Dr Felix Saur will provide insights at the 30th meeting of the Sound and Vibration Working Group (Rail Transport) on Intelligent, mobile lubrication systems using on-board acoustic measurement

We look forward to open discussions, critical questions and the exchange of experiences.

 

BDe 576 railcar retrofitted with an energy measurement system for Makies AG in Switzerland.

Engineering and integrating an energy measurement system

Customer: Makies AG, Switzerland

Project tasks

  • Program management
  • Project planning
  • Electrical engineering
  • Mechanical engineering
  • Technical documentation

Our approach

Makies AG wanted to retrofit the BDe 576 railcar with an energy measurement system. PROSE, together with our workshop partner, carried out this trial installation. PROSE was responsible for the electrical dimensioning, product selection and the final conversion documentation. The workshop partner was responsible for product procurement, installation of the Energy measurement system (EMS) components, wiring and commissioning.

We developed a structured the template for the installation instructions and completed it with all product selection-relevant data for the current and voltage converter, Ecomodul, fuse protection and router. Product selection was defined based on the infrastructure requirements and existing onboard installations, incorporating experience gained from comparable system installation and operation. The final installation documentation includes the complete installation instructions and the product list.

Customer benefit

By commissioning PROSE, the customer benefits from our extensive experience in rail vehicle integration engineering. The proposed mechanical and electrical solutions supported a robust and sustainable energy measurement system installation. Our neutral advisory role ensured effective coordination between all project participants, particularly the workshop, reducing interface risks and supporting efficient implementation.

 

  

Vande Bharat train at platform – sleeping car unit representing bogie design validation project in India.

Design validation of bogies for Vande Bharat sleeping cars

Customer: Ramkrishna Forgings Limited, India

Project tasks

  • Bogie design validation
  • Creation of 3D models for all bogie types
  • FEA of the bogie frame types and high-loaded components
  • Preparation of bogie frame fatigue test specification
  • Welding inspection onsite
  • Update of existing drawings to improve manufacturing quality

Our approach

PROSE was commissioned by RAMKRISHNA FORGINGS LIMITED (RKFL) to perform independent design validation of the bogie assemblies for the new sleeping car coaches of the Vande Bharat train. The work focused on verifying the structural and functional compliance of the existing passenger car bogie for the sleeping car configuration. We performed Finite Element Analysis (FEA) and assessed conformity with relevant railway standards, providing the technical justification required to support the design modifications and approval for operation.

PROSE provided RAMKRISHNA FORGINGS LIMITED (RKFL) with independent technical validation of the bogie design for the sleeping car configuration of the Vande Bharat train. Drawing on our expertise in structural, safety and system analysis, and our deep understanding of international railway standards, we ensured a reliable and efficient assessment of the existing design

Customer benefit

As an independent engineering partner, PROSE supported RKFL from analysis through testing and documentation, helping to secure the operational readiness and approval of the new sleeping cars for service on the Indian rail network. Furthermore, RKFL receives manufacturing documents tailored to RKFL’s production capabilities.

 

    

Intelligent rail head lubrication system using AI to reduce curve squeal, wear and lubrication consumption in urban rail transport

What is possible when rail head lubrication is intelligently controlled?

The results from our research are clear. The following effects were measured on a PoC track in urban operation:

  • −98.5% curve squealing
  • up to −60% lubrication agent consumption
  • Simulations indicate a potential reduction of wheel tread wear of up to 12 %

A key learning for operators: it is not high-end hardware that is crucial, but a robust database, a sensibly defined squeal index, developed together with Substring, and an understanding of wheel-rail contact throughout the entire operation.

Intelligent lubrication reduces conflicting objectives: less noise with lower resource consumption and less wear with more stable life cycle costs. This makes intelligent rail head lubrication a building block for sustainable mobility and consistent lifecycle optimisation in urban rail transport.

These findings form the basis for exchange, further exploration and the next step towards practical application.

For those who want to get more information (only in German):

Urban tram on a tight curve with rail head contact, sparks and digital overlays showing noise, weather data and AI-supported rail lubrication analytics.

Traditional rail head lubrication is reaching its limits – this is why

Urban rail transport is under constant pressure. Tight curve radii, high frequencies, and increasing environmental demands lead to familiar challenges: squealing on curves, increased wheel-rail wear, and the use of lubricants with negative environmental impacts.

Conventional rail head lubrication is largely static, using fixed quantities at fixed locations, regardless of weather or actual need. This often creates a trade-off between noise, wear and environmental impact.

This is where the intelligent rail head lubrication research project comes in. Requirements are determined based on data, using:

  • acoustic sensors directly on the vehicle
  • continuous noise mapping along the route
  • weather and operating data
  • AI-supported evaluation

This means that lubrication is triggered depending on the situation and proactively, based on real operating data. This is the starting point for our research.

More background on the intelligent rail head lubrication research project, including objectives, approach and system architecture, can be found here:

– Project description: https://www.aramis.admin.ch/Default?DocumentID=73688&Load=true

– Project presentation (overview and setup, only in German): aramis.admin.ch/Default?DocumentID=73691&Load=true

Open door of a C20 metro driver cab in Sweden, illustrating onboard modifications and the need for verified electrical documentation.

Documenting a reconstructed electrical design for a metro driver cab air conditioning system

Customer: MTR Tech AB, Sweden

Project tasks

  • Collection of as-built electrical information from customer
  • Technical review and consolidation of handwritten updates
  • Reconstruction of electrical schematics
  • Verification of correctness and consistency
  • Formal release of approved drawings

Our approach

The project addressed the absence of controlled and verified electrical documentation following the installation of a new air-conditioning unit in the driver cab of a C20 metro vehicle operating in Sweden. The modification had been implemented by the customer, with electrical schematics updated manually, resulting in missing traceability, inconsistent information, and non-compliance with railway documentation standards. The objective was to reconstruct the as-built installation, verify the electrical design, and formally document and release correct, complete and compliant electrical drawings.

PROSE collected and reviewed all available technical input from the customer, including as-built installation details and handwritten updates to existing schematics. Based on this information, we analysed, consolidated, and reconstructed the electrical design and documented it into formal electrical schematics in accordance with applicable railway documentation standards. The resulting drawings were verified and issued under PROSE authorship, in close coordination with the customer’s engineers, ensuring accuracy, traceability, and controlled release. PROSE’s independence and deep understanding of railway electrical systems enabled efficient reconstruction even with incomplete and informal source material.

Customer benefit

By selecting PROSE, the customer obtained verified and formally released electrical documentation that accurately reflects the as-built installation. This restored full traceability, ensured compliance with railway documentation standards, and created a reliable basis for safe operation, maintenance, and future modifications. PROSE’s independent engineering approach and experience in reconstructing and validating modified or legacy designs reduced project risk and relieved pressure on the customer’s internal engineering resources.

 

   

Assembly of a red funicular carriage with new air suspension chassis during the modernisation of an alpine funicular railway, accompanied by PROSE.

Chassis development funicular railway

Customer: Steurer Seilbahnen AG, Switzerland

Project tasks

  • Project management
  • Weight management
  • Feasibility study
  • Concept development
  • Verification concept and load assumptions
  • Strength calculation
  • Manufacturing support

Our approach

As part of the modernisation of the funicular railway from Unterwasser to Iltios in the Toggenburg region, Steurer Seilbahnen AG selected PROSE as its partner for the development of a custom running gear with air suspension – specially designed for funicular railway applications.

Steurer Seilbahnen AG has designed an innovative concept for a funicular railway chassis with air suspension and one-sided longitudinal force transmission. Building on this foundation, PROSE worked with Steurer to develop detailed requirements specification and carried out a concept validation. The constructive realisation was carried out at Steurer with technical support and coordination from PROSE. Our team handled the full structural design and strength verification, including equalisation safety. We also defined the measuring point plan for the test runs and delivered a comprehensive comparison report to support strength validation. To ensure an optimal solution, close cooperation between all parties involved was key during the iterations between design and strength.

Customer benefit

The combination of Steurer’s and PROSE’s expertise in funicular railways and air suspension resulted in a constructive and efficient co-operation that always kept an eye on all aspects, right through to verification. PROSE’s flexibility and proactive project management – together with Steurer’s practical insight – enabled design optimisations to be seamlessly integrated during procurement and manufacturing. This close cooperation ensured a technically sound, thoroughly verified solution tailored to the specific needs of funicular railways.

 

        

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