Case Study: Powering India’s Next-Gen Freight Locomotives
Client: Indian Railways
Location: India
Project Year: 2024-2025
Sector: Rail Electrification / Locomotive Engineering
Mahati has been commissioned by Indian Railways to develop and deliver 6531 KVA, 25 kV locomotive transformers for high-speed freight locomotives. This marks a significant step in supporting India’s railway modernisation efforts. The transformer is designed to meet the unique demands of electric locomotives, balancing compact design with high performance under challenging load and track conditions.
Locomotive Transformer in testing at Mahati.
Challenges and Requirements
Mahati worked with the specification provided and adapted its existing traction transformer designs to meet the evolving parameters for Indian freight locomotives.
Solution Highlights:
Rated at 6531 kVA, 25 kV input, with 1269 V x 4 secondary outputs.
Oil-immersed, forced-air cooled design for efficient heat dissipation.
High-precision winding and insulation systems for vibration endurance.
Built to operate in high-humidity and variable-temperature conditions.
Designed with integrated terminals to ease installation into locomotive chassis.
The transformer was manufactured at Mahati’s dedicated unit under full quality control and performance testing.
Implementation & Execution
Due to the nature of traction transformers, Mahati followed a tight design, build, and test cycle:
Engineering Design: CAD-based layout optimised for low-profile mounting.
Manufacturing: Conducted at Mahati’s ISO-certified plant, using copper windings and treated core laminations.
Testing: Routine and special traction transformer tests conducted, including short-circuit, heating, insulation, and vibration tolerance.
Inspection: Supervised by Indian Railways QA engineers.
Transformers were integrated directly into the freight locomotive platform shown during the commissioning process. This included on-site fitment and functional validation under power.
Results & Impact
Transformer accepted and integrated into next-gen freight locomotives.
Voltage regulation and overload tolerance successfully demonstrated.
Compact build and durability confirmed by QA inspectors.
Project delivered on schedule and within performance limits.
Mahati’s success in this delivery affirms its technical readiness to meet the high-spec demands of Indian Railways and other electrified transport agencies.
Future Outlook & Scalability
The transformer was developed with future compatibility in mind. It can be adapted for similar power classes, metro rail requirements, or higher-speed passenger engines. With this supply, Mahati positions itself as a long-term traction transformer partner.
Why Mahati?
Proven track record in traction and special-purpose transformer design.
In-house engineering, manufacturing, and testing under one roof.
Products designed for rugged rail environments.
Scalable expertise to meet India’s transport electrification goals.