Integral Coach Factory

{{short description|Rolling stock production unit under Ministry of Railways (India)}}

{{Infobox company

| name = Integral Coach Factory

| logo =

| logo_size = 75px

| image = Integral Coach Factory, Chennai aerial view.jpg

| image_size =

| image_caption = Aerial view of the ICF in Perambur, Chennai.

| type = Government factory

| industry = Rail transport

| founded = {{Start date and age|1955|10|02|df=yes}}

| hq_location = Chennai, Tamil Nadu, India

| area_served = Asia-Pacific
Africa

| key_people = U. Subba Rao{{cite news|url=https://icf.indianrailways.gov.in/uploads/USR1.pdf|title=U Subbra Rao takes over as General Manager|publisher=Indian Railways|access-date=1 April 2024}}
{{small|(General Manager)}}

| products = {{Bulleted_list|Rolling stock|EMU|MEMU}}

| production = 4,166 coaches (2019–20)
2,702 coaches (2022–23)

| num_employees = 9,300 (2024){{cite web|url=https://icf.indianrailways.gov.in/view_section.jsp?lang=0&id=0,294|title=About us|publisher=ICF|access-date=1 December 2023}}

| parent = Indian Railways

| homepage = {{URL|https://icf.indianrailways.gov.in/}}

}}

Integral Coach Factory (ICF) is an Indian manufacturer of rolling stock, and electrical multiple units. Established in 1955, it is located in Perambur in Chennai and is the largest rail coach manufacturer in the world. It is owned and operated by the Indian Railways and is the oldest amongst the five rake production units of the Indian Railways. While the facility initially manufactured ICF coaches, it currently manufactures LHB coaches and electric multiple units including the semi-high speed Vande Bharat train-sets.

History

After Indian Independence, the Government of India wanted to reduce the import of rail coaches to cater to the increasing traffic of the Indian Railways. In the railway budget for 1949–50, then Minister of Transport and Railways, N. Gopalaswami Ayyangar announced the intention to establish a railway coach factory in India.{{cite report|url=https://icf.indianrailways.gov.in/works/uploads/File/ICF%20-%20Tracing%20The%20%20Roots.pdf|title=Tracing the roots|access-date=1 December 2023|publisher=ICF}}

In 1949, a technical agreement was concluded with Swiss Cars and Elevator Manufacturing Corporation, a Zurich-based company for technical assistance and transfer of coach building technology.{{cite news|url=https://www.deccanchronicle.com/141015/nation-current-affairs/article/integral-coach-factory-strong-60|title=Integral Coach Factory strong at 60|date=15 October 2014|newspaper=Deccan Chronicle|access-date=1 December 2023}} A basic steel shell was designed as a prototype by the Swiss company which would form the basis of coaches to be manufactured in the new facility.{{cite web|last1=N |first1=Sushma U. |title=54,000 coaches later, an Indian train factory is hitting reset for the high-speed age|url=https://qz.com/india/1206751/integral-coach-factory-icf-where-indias-high-speed-train-journey-begins|work=Quartz |access-date=9 August 2024|date=7 March 2018|quote=Since its inception in 1955, the ICF has been running on technology from Switzerland’s Swiss Cars and Elevators Manufacturing and Germany’s Linke-Hofmann-Busch (LHB)}}

In 1951, the site for the factory was chosen at Perambur, a suburb of Madras and the construction began. A further extended agreement was signed in 1953 for the Swiss company to supply tools and machines to set up the factory. The Integral Coach Factory is one of the earliest production units and was constructed at a cost of {{INRconvert|74.7|m|lk=r}}.{{cite report|url=https://eparlib.nic.in/bitstream/123456789/55733/1/lsd_01_06_23-03-1954.pdf|title=Parliamentary debates, 1954|archive-url=https://web.archive.org/web/20200407144730/https://eparlib.nic.in/bitstream/123456789/55733/1/lsd_01_06_23-03-1954.pdf|archive-date=7 April 2020|page=4|access-date=1 April 2020|publisher=Government of India}} The factory was inaugurated by then Prime Minister of India Jawaharlal Nehru,{{cite web|title=Inside the Chennai-based Integral Coach Factory, where Vande Bharat coaches are manufactured |url=https://www.thehindubusinessline.com/scaling-up/videos/inside-the-chennai-based-integral-coach-factory-where-vande-bharat-coaches-are-manufactured/article68592712.ece |access-date=11 December 2024 |work=Business Line |date=1 September 2024 |quote=Inaugurated by the late Prime Minister Jawaharlal Nehru in 1955, ICF, as it is popularly called, has been producing several coaches...}} and rolled out its first coach on 2 October 1955.{{cite news|url=https://www.thehindu.com/news/national/tamil-nadu/integral-coach-factory-a-global-success-story/article65511204.ece|title=Integral Coach Factory: a global success story from Chennai|date=10 June 2022|newspaper=The Hindu|access-date=1 December 2023}} The furnishing division was inaugurated on 2 October 1962.

Manufacturing

File:Stamp of India - 2019 - Colnect 909074 - India Railways Integral Coach Factory.jpeg commemorative stamp]]

The ICF consists of two main divisions, shell division and furnishing division.{{cite web|url=https://icf.indianrailways.gov.in/view_section.jsp?lang=0&id=0,295,329|title=Rolling Stock Department|publisher=ICF|access-date=1 December 2023}} The shell division consists of 14 individual units and manufactures the skeleton of the rail coach, where various parts that form the shell are fabricated and integrated to form a single structure that is placed on wheel sets. The furnishing division consists of eight individual units and is responsible for interior furnishing, exterior painting, electrical equipment and other testing. The factory had an installed capacity of 350 units per annum in 1955 with the production increasing to 1458 by 2013–14, 2277 by 2016–17 and reaching the highest at 4166 coaches in 2019–20.{{cite news|url=http://timesofindia.indiatimes.com/business/india-business/ICF-produces-record-1622-coaches/articleshow/33089541.cms|title=ICF produces record 1,622 coaches|newspaper=The Times of India|access-date=6 April 2014|archive-date=3 March 2017|archive-url=https://web.archive.org/web/20170303122502/http://timesofindia.indiatimes.com/business/india-business/ICF-produces-record-1622-coaches/articleshow/33089541.cms|url-status=live}}{{cite web|url=http://www.railjournal.com/index.php/asia/indian-government-approves-kolar-coach-factory.html?channel=529|title=Indian government approves Kolar coach factory|date=12 March 2014|access-date=6 April 2014|archive-date=20 November 2016|archive-url=https://web.archive.org/web/20161120005757/http://www.railjournal.com/index.php/asia/indian-government-approves-kolar-coach-factory.html?channel=529|url-status=live}}

In 2011, the air-conditioned train-sets manufactured by ICF for Kolkata Metro allegedly broke down causing disruption of services as the rakes were sent to Kolkata without conducting dry runs because the ICF did not have third-rail testing facilities.{{cite news|url=https://timesofindia.indiatimes.com/city/kolkata-/Snag-disrupts-Metro-services-develops-snag-commuters-stranded/articleshow/10024302.cms|archive-url=https://archive.today/20120715021156/http://articles.timesofindia.indiatimes.com/2011-09-18/kolkata/30171837_1_air-conditioned-rake-metro-services-first-ac-rake|url-status=live|archive-date=15 July 2012|title=Snag disrupts Metro services develops snag, commuters stranded|date=18 September 2011|newspaper=The Times of India|access-date=1 July 2012}} As of early 2020s, the company manufactures over 4000 coaches each year and is the largest rail coach manufacturer in the world.{{cite news|date=14 January 2020|title=After becoming world's largest rail factory, Indian Railways ICF to beat its own coach production record|url=https://www.financialexpress.com/business/railways-after-becoming-worlds-largest-rail-factory-indian-railways-icf-to-beat-its-own-coach-production-record-1822460/|access-date=5 May 2024|newspaper=Financial Express}}{{cite news|title=Watch {{!}} How Chennai's ICF became a global success |url=https://www.thehindu.com/news/cities/chennai/watch-how-chennais-icf-became-a-global-success/article65527429.ece|newspaper=The Hindu|access-date=9 August 2024|date=14 June 2022|quote=from manufacturing 350 units per year, now it rolls out over 4,000 coaches annually}} In June 2024, ICF rolled out its 75,000 coach, which was part of the 69th rake of Vande Bharat.{{cite news|title=ICF rolls out 75,000th coach since its inception|url=https://www.thehindubusinessline.com/economy/logistics/icf-rolls-out-75000th-coach-since-its-inception/article68341207.ece|newspaper=The Hindu Business Line|access-date=9 August 2024|date=27 June 2024|quote=Integral Coach Factory (ICF), Chennai, made history on Thursday by rolling out the 75,000th coach since its inception in 1955. The 75,000th coach was part of the 69th rake of Vande Bharat trainset.}}

Products

File:Vande_Bharat_Express_around_Mumbai.jpg semi-high speed train-set built by ICF]]

ICF manufactures more than 170 varieties of coaches including ICF coaches, LHB coaches, Metro coaches, EMUs, DMUs and MEMUs. The coaches manufactured based on original Swiss design were termed as ICF coaches which were manufactured from 1955 to 2018.{{cite news|last=Ayyappan|first=V.|date=4 January 2021|title=Leakage Found in ICF Coaches|newspaper=The Times of India|url=https://timesofindia.indiatimes.com/city/chennai/leakage-found-in-icf-coaches/articleshow/80095746.cms|access-date=6 June 2023}} The ICF coaches were replaced by newer LHB coaches designed by Linke-Hofmann-Busch of Germany.{{cite news|last=Debroy|first=Bibek|date=9 February 2018|title=A 70-Year-Old Vs a 30-Year-Old: LHB Coaches Perform Better than ICF Ones|newspaper=Business Standard|url=https://www.business-standard.com/article/opinion/a-70-year-old-vs-a-30-year-old-lhb-coaches-perform-better-than-icf-ones-118020801725_1.html|url-access=subscription|access-date=6 June 2023}} In the 1960s, ICF started developing EMUs for short-haul and local routes.{{cite report|date=15 October 1999|title=Electrical Multiple Units|url=https://st2.indiarailinfo.com/kjfdsuiemjvcya1/0/8/0/2/4684802/1/multipleunits1091923.pdf|website=Indian Rail Info|access-date=1 December 2023}}{{cite web|title=Historical Background of Railway Electrification|url=https://core.indianrailways.gov.in/view_section.jsp?lang=0&id=0,294,302,530#:~:text=The%20first%20electric%20train%20ran,electrified%20on%201500%20Volt%20DC.|access-date=19 May 2023|publisher=Indian Railways}}

In 2017, ICF started developing a semi-high speed train-set designed to be fully air-conditioned, equipped with modern facilities and capable of reaching speeds of over {{cvt|160|kph}}.{{cite news|date=20 February 2017|title=Indian Railways to roll out 'Make in India' 160 kmph self-propelled 'world-class' train sets at half the cost of import!|url=https://www.financialexpress.com/india-news/indian-railways-to-roll-out-make-in-india-160-kmph-self-propelled-world-class-train-sets-at-half-the-cost-of-imports/558791/|access-date=20 May 2023|newspaper=The Financial Express}} In 2018, the first prototype code-named "Train 18" was completed within 18 months after initiation and was built at a cost of {{INRConvert|970|m|year=2018}} with 80% indigenous components.{{cite news|date=29 October 2018|title=Train 18: Country's first engine-less train rolled out; Train 20 next|newspaper=The Economic Times|url=https://economictimes.indiatimes.com/industry/transportation/railways/train-18-countrys-first-engine-less-train-rolled-out-train-20-next/articleshow/66419774.cms|access-date=20 May 2023|issn=0013-0389}} It was later re-named as Vande Bharat Express, the first of which was flagged off by the Prime Minister of India on 15 February 2019.{{cite news|url=https://www.ndtv.com/india-news/train-18-indias-fastest-named-vande-bharat-express-piyush-goyal-1983965|title=India's fastest to be called Vande Bharat Express|work=NDTV|access-date=22 April 2021|archive-date=28 January 2019|archive-url=https://web.archive.org/web/20190128060002/https://www.ndtv.com/india-news/train-18-indias-fastest-named-vande-bharat-express-piyush-goyal-1983965|url-status=live}}{{cite news|last1=Sivapriyan|first1=E|title=Integral Coach Factory to turn new Vande Bharat variants this fiscal|url=https://www.deccanherald.com/india/integral-coach-factory-to-turn-new-vande-bharat-variants-this-fiscal-2648770|access-date=27 December 2023|newspaper=Deccan Herald|quote=Launched as Train 18 and rechristened as Vande Bharat, the trains that are designed to run at a maximum speed of 180 km per hour are indigenously manufactured at the ICF since 2018}}

Exports

While the coach factory primarily manufactures rolling stock for Indian Railways, it also exports railway coaches to other countries. The first export was an order of 47 bogies to Thailand in 1967 and the factory has since exported 875 bogies and coaches to over 13 Afro-Asian countries including Angola, Bangladesh, Mozambique, Myanmar, Nepal, Nigeria, Philippines, Sri Lanka, Taiwan, Tanzania, Uganda, Vietnam, and Zambia.{{cite news|title=65-year-old ICF of Indian Railway exported 650 rail coaches in last few years to 14 countries|url=https://www.newindianexpress.com/nation/2022/mar/06/65-year-old-icf-of-indian-railway-exported-650-rail-coaches-in-last-few-years-to-14-countries-2427078.html|access-date=30 April 2023|newspaper=The New Indian Express|archive-date=30 April 2023|archive-url=https://web.archive.org/web/20230430105339/https://www.newindianexpress.com/nation/2022/mar/06/65-year-old-icf-of-indian-railway-exported-650-rail-coaches-in-last-few-years-to-14-countries-2427078.html|url-status=live}}{{cite news|date=18 May 2018|title=Chugging through TN's Integral Coach Factory, India's oldest train-making facility|url=https://www.thenewsminute.com/article/chugging-through-tn-s-integral-coach-factory-india-s-oldest-train-making-facility-81541|access-date=30 May 2023|work=The News Minute|language=en|archive-date=30 April 2023|archive-url=https://web.archive.org/web/20230430110842/https://www.thenewsminute.com/article/chugging-through-tn-s-integral-coach-factory-india-s-oldest-train-making-facility-81541|url-status=live}}{{cite news|title=Janakpur-Jayanagar rail service to resume operations by March|url=http://kathmandupost.com/money/2020/01/16/janakpur-jayanagar-rail-service-to-resume-operations-by-march|access-date=30 April 2023|work=Kathmandu Post|archive-date=30 April 2023|archive-url=https://web.archive.org/web/20230430105341/http://kathmandupost.com/money/2020/01/16/janakpur-jayanagar-rail-service-to-resume-operations-by-march|url-status=live}}

Other facilities

A training school, established in 1955 provides training to the personnel. A Regional Railway Museum is situated in the factory premises which has a collection of nascent models of trains and models endemic to the Indian Railways. ICF maintains quarters of working staff and other associated facilities including hospitals and schools. About 59.1 million units of electricity had been generated through the windmills installed by ICF in Tirunelveli district in 2011 which met 80 per cent of the plant's electrical energy requirements.{{cite news|url=http://www.business-standard.com/india/news/coach-factory-to-use-rs-250-cr-to-upgrade-bogies/462943/|title=Coach factory to use Rs 250 cr to upgrade bogies|work=Business Standard|date=27 January 2012|access-date=19 February 2012}}{{cite news|url=http://articles.timesofindia.indiatimes.com/2010-02-23/chennai/28139780_1_cfl-bulbs-surplus-power-windmills|archive-url=https://archive.today/20120707145128/http://articles.timesofindia.indiatimes.com/2010-02-23/chennai/28139780_1_cfl-bulbs-surplus-power-windmills|url-status=dead|archive-date=7 July 2012|title=Surplus from ICF windmills to power TNEB grid soon|newspaper=The Times of India|date=23 February 2010|access-date=19 February 2012}}{{cite news|url=http://www.hindu.com/2009/04/10/stories/2009041054990500.htm|archive-url=https://archive.today/20120907172303/http://www.hindu.com/2009/04/10/stories/2009041054990500.htm|url-status=dead|archive-date=7 September 2012|title=Integral Coach Factory installs seven windmills|newspaper=The Hindu|date=10 April 2009|access-date=19 February 2012|location=Chennai, India}}