Knorr-Bremse Rail Systems UK has achieved a key milestone during the first of three planned overhaul periods as part of an eight-year contract to repair and overhaul 510 sanitary systems fitted to the Alstom-built Class 390 Pendolino fleet.
A key focus of the programme’s early stages has been an intensive mobilisation phase undertaken by Knorr-Bremse’s specialist team in Calne, Wiltshire, working closely with Alstom to return critical float stock to service while establishing a sustainable long-term overhaul operation.
Since the programme commenced in September 2025, the Calne team has successfully overhauled 425 sanitary units to date. During the initial mobilisation period, Knorr-Bremse significantly increased its overhaul output to deliver between 15 and 18 sanitary unit overhauls per week – equivalent to the sanitary systems fitted to two complete Pendolino trainsets.
This concentrated effort enabled 50 float units held at Alstom’s Liverpool Traincare Centre to be overhauled and returned to service within a short timeframe. The float stock is used to support maintenance activities across the Pendolino fleet and can be deployed to train depots around the country as required.
The accelerated programme was developed jointly by Knorr-Bremse and Alstom to meet an immediate operational requirement before transitioning to a sustainable long-term overhaul schedule. By rapidly replenishing the float stock pool, the programme helped ensure there was no impact on fleet availability or wider maintenance activities.
Jack Durkin, Business Manager at Knorr-Bremse Rail Systems UK, said:
“The mobilisation phase of this programme has been a tremendous achievement and demonstrates the strength of the partnership between Knorr-Bremse and Alstom. Our team in Calne went above and beyond to increase overhaul capacity during the early months of the contract, enabling us to quickly return 50 float units to service and support fleet availability across the Pendolino network. We are extremely proud of the commitment shown by the team and the progress achieved so far.”
A leading supplier to the rail industry, Knorr-Bremse has more than 30 years of experience in integrated sanitary systems. The original systems fitted to the Pendolino fleet were supplied by Evac, which became part of Knorr-Bremse following its acquisition in 2021, providing extensive expertise in the maintenance and lifecycle support of these systems.
The overhaul process begins with the removal of sanitary units before they are transported to Knorr-Bremse’s dedicated facility in Calne. Each unit is fully stripped down and assessed, with key components including vacuum pumps, sliding gate valves and solenoid valves inspected, refurbished or replaced as required. Following reassembly, every unit undergoes comprehensive testing before being returned for reinstallation.
Simran Sandhu, Senior Procurement Project Manager at Alstom said:
“The successful mobilisation of this programme is a testament to the strong collaboration between Alstom and Knorr-Bremse. Establishing the overhaul operation while rapidly returning critical float stock to service has been essential in supporting the continued availability of the Class 390 fleet. Knorr-Bremse’s technical expertise, responsiveness and commitment throughout the mobilisation phase have helped ensure a smooth transition into long-term delivery, and we look forward to continuing our partnership over the course of this programme.”
The long-term agreement reflects Alstom’s confidence in Knorr-Bremse’s specialist sanitary system expertise and aftermarket support capabilities. With more than 200,000 sanitary systems supplied worldwide, Knorr-Bremse is recognised as a global leader in rail sanitary technology.
The overhauled systems will continue to support the reliability, comfort and operational performance of the Class 390 Pendolino fleet, one of the UK’s most important long-distance passenger fleets.