Flexible car transport: DB Cargo Logistics sets the standard

Flexible logistics solutions are playing an increasingly important role in the rapidly changing automotive industry. DB Cargo Logistics recognised this development early on and reacted accordingly in the interest of its customers: With flexible car carrier wagons, the DB Cargo subsidiary offers state-of-the-art solutions for transporting a wide range of vehicle types, from classic compact cars to large SUVs and heavy electric vehicles.

New requirements – new equipment

The demand for SUVs and electric cars has risen sharply in recent years. Both vehicle types place specific demands on car transport: SUVs are heavier, wider and higher than the vehicles that have been common for decades, while electric cars also have a higher weight and often lower ground clearance due to the battery – similar to that of sports cars. These circumstances are fundamentally changing the demand for rail equipment.

The SUV trend is changing the requirements for rail transport.

The development of flexible car carrier wagons began at DB Cargo Logistics over a decade ago. "From the close exchange with our customers and market analyses, we recognised early on that a rigid structure for car carrier wagons was no longer sufficient to meet changing requirements," explains Kai Birnstein, Head of Automotive at DB Cargo Logistics. Malte Keller, Head of Equipment, adds: "We started modernising our existing wagons back then. Also we put a lot of energy into developing new wagons for car transport." 

The wagon's flexible upper loading level is the key here. It makes it possible to adjust the loading height individually and thus optimally utilise the loading volume. The lower level is loaded with vehicles and then the upper level is lowered as far as possible before it is also loaded. This provides a significant gain in space, allowing tall SUVs to be transported double-decker on the wagon without exceeding the permissible loading gauge. 
 

The upper loading level of modern car carrier wagons can be infinitely adjusted – for maximum loading flexibility.

Proximity to the customer and continuous development

A decisive factor for the success of the flexible car carrier wagons is the close cooperation with the car manufacturers. Their requirements are collected before development begins. DB Cargo Logistics then presents the prototype of the new or enhanced wagon as part of a roadshow to test its functionality and efficiency under real-life conditions. In the end, customer requirements, feasibility and costs are compared before the wagon finally goes into series production.

Advantages of the flexible car carrier wagon at a glance

Ideally equipped for plants with full-flex production

With the development of flexible wagons, DB Cargo Logistics is also adjusting optimally to the changing production concepts of car manufacturers. The conversion of many plants to "full-flex production" means that different vehicle models can be manufactured on one production line at one plant. This increases the transport requirements, as different vehicles have to be transported in one train. Here, the flexible wagons offer a clear advantage and ensure that a double-decker wagon can accommodate small cars and SUVs in parallel, for example.

"The challenge was to develop a wagon that was flexible enough to meet the changing demands of the market, but at the same time robust and affordable. Our engineers have done a great job here."

Kai Birnstein, Head of Automotive at DB Cargo Logistics

Efficient and environmentally friendly transport

The new generation of wagons also offers the advantage of a higher load limit and is designed for individual weights of up to 3.2 tonnes. This enables higher capacity utilisation per train, which reduces transport costs and increases competitiveness on the railways. A comparison with lorries shows: While the latter can only transport five to six vehicles, the flexible wagons on the railway can manage ten to twelve cars – per wagon!

Thanks to the flexibly adjustable upper loading level, the available loading space can be optimally utilised on a train.

In addition, transport concepts with flexible wagons make it easier to integrate return loads for other customers and avoid empty runs. "All of this not only makes us competitive on the railways, but also significantly increases our already existing environmental benefits," says Birnstein. "Full-flex is the new standard for us."

Global procurement and development partnerships

In order to fulfil the increasing demands of the market, DB Cargo Logistics not only relies on European manufacturers, but has also searched for the best partners worldwide. "There are only a few manufacturers who are able to fulfil our high requirements for flexible car carrier wagons," explains Malte Keller. "We have done pioneering work by enabling manufacturers to produce this type of equipment in the first place through years of intensive development phases." By diversifying its supplier portfolio in this way, DB Cargo Logistics is not only ensuring that its own customers have access to a state-of-the-art fleet but is also making a significant contribution to ensuring that the European rail logistics provider can procure the required number of flexible wagons for the automotive industry in the future.

There are only a few manufacturers in the world that are able to fulfil the complex requirements of building flexible car carrier wagons.

DB Cargo Logistics demonstrates that innovative solutions and proximity to the customer are crucial to asserting oneself in a dynamic market environment. With its flexible car carrier wagons, the company has already set a new standard that fulfils the requirements of tomorrow's automotive industry.