01

Results at a Glance

• 30 to 40% improvement in operational efficiency

• 13.3% increase in LTI-free days, now exceeding 1,700 days

• Facility designed with potential to double the workforce

• 228-kilowatt rooftop solar system installed

• Delivered on time and within budget
  

02

Client Overview

Vossloh is Australia's market leader in rail switch manufacturing and concrete sleepers, supplying nationally significant rail expansion projects across Southern and Eastern Australia. Their Castlemaine facilities could no longer support that role.

Outdated layouts, limited capacity, and a production floor that demanded full factory shutdowns every time a long rail needed to move, the inefficiencies were built into the building itself. For a business contributing to Australia's major rail programs, that was not a sustainable position.

A private property developer in Bendigo held the site and the opportunity. They needed a facility that would work for a highly specialised tenant. Vossloh needed a facility that would keep them competitive for the next generation of contracts. Entegra was brought in to deliver for both.

03

Key Outcomes

Vossloh Australia has moved switch production from Castlemaine to a new 6,800m² facility in Bendigo, with Entegra delivering the turnkey design and construct on time and within budget. The build was a partnership across all three parties, balancing the developer's long-term investment against the tenant's operational requirements from feasibility through to handover.

At Castlemaine, moving 10 to 13 metre rail required full production stoppages. The new layout allows 27.5 metre rail to run end to end without interruption, delivering the 30 to 40 per cent efficiency improvement reported by the operations manager.

Safety performance has improved alongside production. LTI-free days are up 13.3 per cent and now exceed 1,700, with Vossloh able to manufacture up to 200 railroad turnouts annually from the new site.

Eleven integrated overhead gantry cranes handle the heavy lifting across the floor, removing the bottlenecks and manual handling that constrained the Castlemaine operation. A 228-kilowatt rooftop solar system supports Vossloh's sustainability commitments, and the facility has been designed with room to double the workforce as Vossloh meets demand for Australia's rail infrastructure pipeline. Natural lighting and improved environmental controls have also reshaped the working environment, supporting Vossloh's position as a regional employer of choice.