Shuttlewagon Overcomes Competitor inefficiencies

Case Study

One of the world’s largest rice milling and marketing companies sought a reliable solution for efficiently moving railcars within their facility and exchange them with two major railways. After over a decade of reliability issues, traction failures, and constant downtime with a competitors machine, they turned to Shuttlewagon for a better solution.

The Application

Railcar movers are critical to this facility’s everyday operation. Cars must be moved into the facility for loading and then transported out for distribution across the country. On any given day, crews move between 15 to 30 railcars on a track with a grade ranging from 0.5% to 2% grade. The rails are constantly busy, and the work demands that the equipment performs every time without loss in efficiency.

The Challenge

There was no shortage of challenges with the competitors machine, including:

Lack of tractive effort needed to move the loaded railcars.
Issues moving even 1 to 2 empty railcars at 2% grade.
Steel wheels slipping and damaging the track surface.
Weight-transfer system causing derailments and bending the center pins of empty railcars.
Inability to safely brake at steeper grades, leading to sliding accidents.
Issues finding replacement parts, or receiving them in a timely manner.

These persistent railcar moving challenges were escalating costs, compromising employee safety, and diminishing labor efficiency. The crew was working extended overtime to make up for lost time, and management struggled with growing maintenance expenses and damaged rail infrastructure.

Our Shuttlewagon has been tested under some of the toughest conditions, and it hasn’t missed a beat. The reliability of the equipment and the professionalism of the team behind it have been outstanding. I can't recommend them enough.

~ Railroad Operations Supervisor

The Solution

Recognizing the unsustainability of their current railcar mover, the customer invested in a Shuttlewagon Navigator 5025.

The decision proved transformative, delivering significant improvements in efficiency, traction, and operational reliability.

Impressed by the results, the customer subsequently mandated Shuttlewagon adoption across all their facilities.

Benefits & Data

Labor Savings

Before the switch, their previous railcar mover’s limited capacity forced the 5-person rail crew to work extreme hours to move a small amount of cars. After switching to Shuttlewagon, the crew now finishes on time with far less strain, reducing labor hours by 40%.

Production & Maintenance Costs

Since commissioning the Shuttlewagon, delays in production immediately dropped. The rubber-tire drive system provided the necessary tractive effort, while being gentler on their rails, preventing costly repairs and extending the life of the track. The smooth workflow meant fewer interruptions and better utilization of labor and equipment.

Safety

The competitor railcar movers inability to stop safely on the facility’s 2% grade posed serious safety risks for personnel, pedestrians, and nearby traffic. Shuttlewagon gave the operator full control to stop precisely at the bottom of the hill and resume back up the hill without issue, eliminating one of the sites’ most serious safety hazards.

Conclusion

A railcar mover represents a critical operational investment, and for this customer, the wrong choice led to years of frustration and inefficiency.

Recognizing the pivotal role of this equipment, their strategic switch to a Shuttlewagon delivered immediate, tangible benefits in reliability, safety, and overall performance.

Continuous Improvement

At Shuttlewagon, innovation is more than a goal – it’s a commitment. We are committed to ensuring our railcar movers not only meet the current industry challenges, but anticipating and solving the demands of tomorrow. Our team is continuously analyzing data, customer feedback, and emerging technologies to ensure that we are at the forefront of the next generation of railcar movers.