Plasser & Theurer looks back on a successful InnoTrans 2026: focus on new machines and digital technologies
30 years of InnoTrans in Berlin – the world’s leading trade fair for transport technology has developed into a flagship platform for innovation and knowledge-sharing within the rail industry.
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Plasser & Theurer has been part of this success story for many years. Together with customers and partners, the company used this year’s event to discuss solutions to the challenges facing tomorrow’s railway infrastructure. The focus of the trade fair appearance was on new generations of machines, connected maintenance, and innovations in spare parts.
Plasser UnimatExpress 2X-4x4 Dynamic, the new all-rounder
With the Plasser UnimatExpress 2X-4x4 Dynamic, Plasser & Theurer unveiled a new generation of high-capacity universal tamping machines in Berlin. The continuous-action 2-sleeper tamping machine is specifically designed to meet the increasing regulatory requirements of the European market. ETCS equipment, a resilient machine control system, and state-of-the-art assistance systems are combined with high output and flexibility in plain-line track and turnout applications, resulting in a powerful overall performer.
The tried-and-tested 09/4S technology’s continued development attracted considerable international interest. One of the highlights of the trade fair was the handover of the UnimatExpress on display to OHLA ŽS, a.s. from Brno (Czechia). The machine is the most modern in the company’s fleet and the first of its kind in Czechia to be equipped with the ETCS. For Plasser & Theurer, this handover underlines the successful alignment of its machine portfolio with the requirements of European rail infrastructure managers and construction companies.
Plasser BallastMaster 410, the trade fair debut
The new Plasser BallastMaster 410 enables cost-effective and resource-efficient ballast management. A 10 m³ ballast hopper ensures that the ballast is distributed and inserted exactly where it is needed. Thanks to one-pass technology, ballasting, profiling, and sweeping are carried out in a single work sequence. The sweeper brush can be adjusted to suit different types of sleepers at the push of a button.
In the future, the BallastMaster 410 will be used in conjunction with the UnimatExpress as a mechanized track maintenance train at OHLA ŽS, a.s. Multiple Traction Control allows both machines to be controlled from a single driving control station during transfer travel. This collaboration is a prime example of how Plasser & Theurer optimizes work processes and boosts the efficiency of maintenance operations through tailored machine designs.
10 years of E³ in customer applications: a vision becomes reality
Another highlight of the trade fair appearance was the ten-year anniversary of E³ technology (E³ stands for “Economic, Ecologic and Ergonomic”) in customer applications. Back in 2016, Plasser & Theurer handed over the first hybrid-powered tamping machine to Krebs Gleisbau at InnoTrans. This marked the beginning of a success story that impressively demonstrates how environmental and economic benefits can be combined. Together with representatives from Krebs Gleisbau and Swiss Federal Railways (SBB), Plasser & Theurer CEO Johannes Max-Theurer looked back on the pioneering phase:
“What began as a series of bespoke E³ projects has now developed into a range of solutions for numerous applications in track maintenance. Being the first to invest in this sort of technology takes conviction. It requires trust in the people who develop it. And it requires a willingness to work together to resolve even those issues that only become apparent as we put the ideas into practice. Krebs has given us this trust. We still appreciate that today.”
Oliver Ludwig, CEO of Krebs Gleisbau, emphasized in his speech: “It is a success, a great shared success. The 09-32/4S Dynamic E³ operates reliably and efficiently across all its components. The project has demonstrated that innovation, courage, and collaborative partnership lead to sustainable results."
The operational report confirms the approach taken here: in approximately 1,500 shifts, the machine operated on electric power for more than 70 per cent of its working hours. This resulted in savings of nearly 470,000 litres of diesel. In the meantime, Krebs now operates a second E³ machine.
Plasser Diagnostics and data-driven maintenance
With Plasser Diagnostics, Plasser & Theurer has unveiled a further component of its strategy for connected maintenance: it combines long-standing expertise in digital track surveying with measuring and testing technologies, inspection services, and data-driven solutions. By creating Plasser Diagnostics, a single point of contact has been established for track diagnostics worldwide.
Condition data relating to tracks and turnouts can be accurately captured, localized, and analysed in real time while travelling on a wide variety of rail vehicles. Continuous data collection provides the basis for predictive maintenance that is tailored to requirements. Turnouts and their components are infrastructure assets of particular importance to safety. Plasser TurnoutGeometry measures them under dynamic load conditions and without personnel in the danger zone during regular operations. For Plasser & Theurer, this represents a key lever for increasing infrastructure availability in the long term:
“With Plasser Diagnostics, we are strengthening the knowledge base for maintenance decisions. “This makes it possible to identify precisely what the infrastructure needs, where action is required, and when it will deliver the greatest benefit,” explained Johannes Max-Theurer at the official launch of Plasser Diagnostics in Berlin.
Autonomous track maintenance machines
Plasser & Theurer is also consistently driving technological development in the field of automation. Digital systems, such as Plasser TampingControl, enable automatic adjustment of tamping parameters and continuous quality control through sensor-based real-time measurements. This unburdens operating staff and helps to ensure greater precision and process reliability.
The automation of individual maintenance tasks forms the basis for the next stage of development: increasingly autonomous, interconnected track maintenance machines. Plasser & Theurer’s aim is to intelligently integrate machines and processes, which further standardizes and optimizes maintenance.
Retrofits and original spare parts
In addition to new developments, the modernization of existing machines is becoming increasingly important. Plasser & Theurer, in collaboration with companies such as Plasser Robel Services, offers solutions which bring tried-and-tested track maintenance machines up to the latest technical standards and extend their service life. The Original Retrofit is a key component of the full-service approach, combining cost-effectiveness with the responsible use of resources.
Original spare and wear parts in OEM quality also make a significant contribution to machine availability and to reducing life cycle costs. Drawing on its technical expertise and bespoke spare parts strategies, Plasser & Theurer helps its customers maintain the performance of their machines in the long term. Recycling and refurbishment programmes for selected components complement the range of services and promote sustainability in fleet operation.
InnoTrans 2026: a strong signal for the future
With around 175,600 trade visitors from 128 countries and 3,190 exhibitors, InnoTrans 2026 set new records. For Plasser & Theurer, the trade fair served as confirmation of its strategic direction. The machines, digital technologies, and service concepts presented there demonstrate how cost-effectiveness, sustainability, and automation can be combined to form holistic solutions.
Plasser & Theurer at InnoTrans 2026: the most important facts
What new products and services did Plasser & Theurer showcase at InnoTrans 2026?
The Plasser UnimatExpress 2X-4x4 Dynamic universal tamping machine, the Plasser BallastMaster 410, the new track diagnostics brand Plasser Diagnostics, as well as solutions for automation, retrofits, and original spare parts.
What are the key features of the new Plasser UnimatExpress 2X-4x4 Dynamic 2-sleeper universal tamping machine?
The Plasser UnimatExpress 2X-4x4 Dynamic is a continuous-action, 2-sleeper universal tamping machine for plain-line track and turnouts. It is the next stage of development of the 09/4S technology and has been designed to meet the increasing regulatory requirements of the European market including, among other things, ETCS equipment, resilient machine control and assistance systems.
What advantages does the new Plasser BallastMaster 410 offer for ballast management?
The Plasser BallastMaster 410 ballast profiling machine features a 10m3 ballast hopper and one-pass technology for ballasting, ballast profiling, and sweeping in a single work sequence.
What savings does Plasser & Theurer’s E3 technology deliver in practical use?
Krebs Gleisbau’s first hybrid tamping machine operated on electric power for more than 70 per cent of its working hours over approximately 1,500 shifts, saving nearly 470,000 litres of diesel in the process.
How does Plasser Diagnostics support predictive maintenance?
Plasser Diagnostics combines measuring and testing technologies, inspection services, and data-driven solutions to assess the condition of infrastructure and plan maintenance measures in line with requirements.
How is Plasser & Theurer continuing to develop the automation of track maintenance machines?
Plasser TampingControl, for example, automatically adjusts tamping parameters on the basis of sensor-based real-time measurements and continuously monitors the quality of the work. This improves precision and process reliability and is an important step towards the development of increasingly autonomous track maintenance machines.
What does Plasser & Theurer offer for existing machines?
Plasser & Theurer modernizes existing track maintenance machines using original retrofits, which extends their service life. Original spare and wear parts in OEM quality, as well as refurbishment programmes for selected components, optimize life cycle costs.
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