A team of 15, including 13 journalists from Tamil Nadu and 2 officials from the Press Information Bureau (PIB), visited the state-of-the-art Rail Wheel Factory in Saran (Chhapra), Bihar today. The visit was organized by the Chennai Press Information Bureau.
This factory is one of only two government-owned foundries in India that manufacture railway wheels using casting technology. The group was given a rare opportunity to see the facility up close.
Managed by Indian Railways, the factory was launched in 2008 with an investment of ₹1,600 crore. It plays a crucial role in keeping the country's trains running safely. Speaking to the visitors, R. R. Prasad, Principal Chief Mechanical Engineer (Wheel & Rolling Stock Production), said, “Every train runs on wheels—and those wheels are made here. They might look simple, but the effort that goes into making each one is immense. We rarely get a chance to show the world how much work happens behind the scenes.”
Located in the heart of an agricultural district, the Saran plant is a Greenfield project. It has become a vital hub for industrial development in North India, supplying high-quality wheels to passenger coaches, wagons, and freight trains across the entire Indian Railways network.
During their visit, the delegation toured the plant’s advanced production line. They observed the entire process—from cutting and melting iron in electric arc furnaces at 1700°C, to precision casting, heat treatment, final shaping, and rigorous quality inspections. Every rail wheel undergoes strict quality control checks, including Magna Glow and ultrasonic tests, to ensure it meets the demanding safety and durability standards required for India’s heavy and high-speed rail network.
“Our wheels are engineered to handle heavy loads, continuous vibrations, and the extreme heat generated by braking. You can only truly understand the complexity when you see it in person—it’s a blend of cutting-edge technology and craftsmanship,” Mr. Prasad added.
The Saran factory’s commitment to quality and innovation stands as a testament to Indian Railways’ ongoing efforts to modernize infrastructure and provide millions of passengers with safe, reliable journeys.
A key goal of the factory is to reduce India’s reliance on imported railway wheels by boosting domestic production. The plant supplied just 154 wheels when it started distribution in 2013-14, but delivered 60,699 wheels in 2025-26. The target for 2026-27 is 72,000 wheels, of which 18,261 have already been supplied so far this year. The long-term goal is to supply up to 100,000 wheels annually.
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Each wheel costs about ₹100,000 to produce and weighs between 500 to 525 kg. Large train wheels measure up to 1,000 mm in diameter and are sent for recycling once they wear down to 925 mm. On average, a wheel is used for about 300,000 kilometers.
For safety reasons, artificial intelligence hasn’t yet been integrated into the actual manufacturing process; the plant still relies on human skill and expertise. AI is currently used only in data management tasks.
P. Velmurugan
Central Bureau of Communication
Tirunelveli