KiwiRail, NZ’s only national rail operator, moves around 25% of New Zealand’s exports, transports more than one million tourists and helps enable 34 million commuter journeys a year.

Project Overview

KiwiRail commenced an upgrade of their brake testing system. The best and most efficient system required external metal couplings for air testing. This coupling will be exposed to the elements and collection of dust and dirt. Hence, they wanted a simple solution to cover/cap these couplings.

The Challenge.

The client needed the cap to be durable and remain attached through high-speed travel and various rugged environments. They also had five different types of braking systems that required easy identification to determine the unique test for each system.

The Solution.

Action Plastics applied their extensive polymer knowledge to determine the correct polymer that would remain stable for long term exposure to the harsh environments. We also proposed a multiple colour system so the KiwiRail technicians could easily identify the braking system on the carriage. We developed a tool that would produce a cap that would hold tight yet be flexible enough to be removed manually by hand.

Final Outcome.

The result was a range of five caps in different colours. These caps are applied easily and can be removed and replaced for brake testing. Prior to removal the technicians can identify by the cap colour the brake testing regime they are to carry out.

KiwiRail have been very pleased with Action’s design and end product, and we now export the caps to the offshore manufacturer of KiwiRail locomotives and carriages.