Hitachi adds welding facility to Newton Aycliffe factory

Hitachi Rail has installed a welding facility for train bodyshells at its Netwton Aycliffe factory.

In the latest development of its manufacturing facility at Newton Aycliffe in County Durham, Hitachi Rail has completed new welding and painting facilities that will be used to build the next generation of intercity trains for East Midlands Railway and Avanti West Coast.

Around 40 staff and newly graduated welders and painters will be completing the high-tech aluminium carriage shells, which are a signature of Hitachi’s intercity fleets.

Up to now, pre-welded carriage bodies have been imported from Hitachi’s plant at Kasado, Japan. Now, the North East train builder has invested £8.5 million to create bespoke welding and painting facilities within the factory. It comes at a time when over 230 carriages due to be welded at Newton Aycliffe.

Welding a bodyshell from the inside.

The investment has also involved an extensive upskilling programme for staff and apprentices, including an eight-week initial training programme for welding certification, then further training to obtain additional specialist qualifications. This new training has created a new skills-base that will benefit the workforce and the factory, delivering current and future projects.

Hitachi established its North East manufacturing base, with its 700 strong workforce, in 2015, to build 122 trains as part of the Government’s Intercity Express Programme, along with 70 zero-emission Class 385 regional trains for Scotland.

Since then, Hitachi Rail has focused on localising its supply chain in the UK with whom is has already spent £1.8 billion since 2013, which includes over 130 separate North East suppliers.

Apprentices have been trained in using the new facilities.

The new manufacturing capabilities at the factory is allowing Hitachi Rail to further expand its UK supply chain. New domestic suppliers include AES in Glasgow, Airblast in Peterborough and KM Tools in Stoke-on-Trent. Meanwhile, the expansion in scope of Newton Aycliffe has resulted in Hitachi Rail increasing its existing relationship with North East firms such as Dyer Engineering and Hydram Engineering.

Grant Shapps, Secretary of State for Transport.

Secretary of State for Transport Grant Shapps said: “It is fitting that Hitachi Rail are building the next generation of intercity trains in County Durham, a place with a proud and illustrious railway heritage.

“Their long-term commitment and continued investment in the North East is a major boost for jobs and skills, driving economic growth and helping levelling up our country as we build back better from the pandemic.”

Jim Brewin, Hitachi Rail.

Jim Brewin, Hitachi Rail’s head of UK & Ireland, added: “The £110 million we have now invested at Newton Aycliffe is not only a sign of our continued commitment to the North East of England but also British manufacturing and its supply chain.

“At the heart of our commitment is the continued development of a highly skilled and dynamic workforce, which through our South Durham Technical University College partnership and 70 apprenticeships will drive the rail industry forward at home and abroad for many years to come.”

The new welding and painting facility will allow the North East factory to be more globally competitive, with the capacity to export a wide range of products from metros to commuter and high-speed trains. Target markets include northern Europe and the Middle East, with the firm’s increasing leadership in battery trains broadening potential opportunities.

Last year Hitachi Rail partnered with Hyperdrive Innovation to develop battery packs that can power trains and help the UK meet its Net Zero 2050 targets. This partnership helps create a pathway for batteries to be installed at Newton Aycliffe and could make the North East a hub for battery technology.

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