Pneumatics for the railway industry - cylinders, valves and control systems
We supply pneumatic and hydraulic components for the railway industry: for the construction of new vehicles, the modernisation of older systems and the maintenance of machines. We manufacture catalogue components, replacement parts and custom-engineered designs where a standard product does not fit the existing installation.
What is pneumatics for the railway industry?
Railway pneumatics includes components that use compressed air to actuate, control, lock and secure functions in rail vehicles and railway machines. This group includes pneumatic cylinders, valves, solenoid valves, filters, control panels and air preparation systems.
Railway equipment operates in demanding conditions - under vehicles, in dust, moisture, vibration and variable temperatures. That is why components are selected differently than in light automation. Durability, environmental resistance, repairability and compatibility with the existing installation matter more than only the catalogue port size.
Where are CPP PREMA products used in railway applications?
CPP PREMA products operate as actuating, control, filtration and safety components in freight rolling stock, track machines and infrastructure maintenance vehicles.
| Application area | Typical products | Function in the system |
|---|---|---|
| FALNS / FALS self-discharging wagons | Pneumatic cylinders, directional control valves, filters, control panels | Opening and closing hatches, discharge control, locking |
| Track machines | Custom cylinders, valves, solenoid valves, air preparation units | Securing assemblies, controlling working functions |
| Maintenance trains | Solenoid valves, directional valves | Remote control of a cassette, selection of travel direction |
| Modernisation of older systems | Replacement valves and solenoid valves, sub-base components, repair kits | Restoring function without rebuilding the entire installation |
| Construction of new vehicles and subassemblies | Pneumatic cylinders, valves, filter-regulators, hydraulic cylinders, custom designs | Component selection for a new system or working module |
Pneumatic products for railway applications
Pneumatic cylinders
Rod-type, compact and round cylinders, including special versions such as stainless steel piston rods, modified strokes, stronger magnets and VITON seals. They open hatches, lock mechanisms and operate as actuator drives.
Directional control valves
They direct compressed air flow and control cylinder movement. Compatibility with the existing mounting plate and easy servicing are important - this is why railway versions include, among others, G1/2 sub-base mounted valves.
Solenoid valves
Electrical signal control for remote and modernised systems. We manufacture replacements for components that are no longer available on the market, with functional and mounting compatibility.
Filters and filter-regulators
Compressed air preparation and protection of valves and cylinders against contamination - including series 58 filter-regulator units in railway versions.
Control panels and control boxes
Operation of pneumatic functions from a defined location on the vehicle - combining valves, signalling and pneumatic logic with safety elements.
Check valves and auxiliary valves
Check, shut-off and flow control valves - for safety, flow direction, pressure locking and movement speed control.
Pneumatics or hydraulic power in a railway application?
In rolling stock and railway machines, both systems often operate together. The choice depends on the required force, rigidity and operating character, not on design habit.
Pneumatics
Pneumatics works well for control, hatch opening, locking and auxiliary functions. Its advantages include simplicity, clean operation, fast switching, easy servicing and resistance to contamination.
Hydraulic power
Hydraulic power is selected where high force, rigidity and stable operation under load are required. CPP PREMA also supplies hydraulic cylinders for such applications.
Pneumatic systems for FALNS and FALS wagons
FALNS and FALS self-discharging wagons require control systems for opening hatches during the discharge of bulk materials. Pneumatics is responsible here for movement, control, locking and operational safety, and the system must work repeatedly under railway operating conditions.
A typical system includes a control panel, actuator cylinders, G1/2 sub-base mounted valves and an air preparation filter. The full system structure, components and projects are described on a dedicated page.
Track machines, replacements and wagons - go to details
Full technical descriptions, catalogue numbers and projects for individual areas are available on dedicated pages:
Projects and references
Selected projects show the scope of our competence - from serial production of railway cylinders, through dedicated sub-base mounted valves for railway applications, to hydraulic power systems for wagon manufacturers. Names are provided with consent; the version in brackets can be used for possible industry anonymisation.
| Customer | Scope of work | Component / type |
|---|---|---|
| Railway infrastructure manager | Production of a series of railway cylinders in multiple strokes (150-400 mm), several dozen units | Cylinders from series 18.2609 / 18.2611 / 18.2614 / 18.2615 |
| Railway infrastructure manager | Repair kits for rolling stock maintenance. | Repair kits for cylinder 18.1338 |
| Rolling stock diagnostics | Blocked cylinder manufactured in series for a diagnostic system | Cylinder 18.1338, D80x170 / D50x25 |
| Railway supplier / integrator | Dedicated sub-base mounted valves for railway applications with documentation and operating instructions, and a cylinder for self-discharging wagons | Sub-base mounted valve 24.0401.4312 SPM (G1/2); D390 cylinder for 411V wagons |
| Wagon equipment manufacturer | Production of cylinders for rolling stock in series (up to 500 units) - returning customer | Cylinders 18.3464 |
| Wagon manufacturer | Hydraulic power system - special device for straightening wagon headstocks according to the customer's documentation | Special hydraulic device |
| Railway rolling stock facility | Special compact cylinder, sub-base mounted valves and railway filters - returning customer | D50x35 cylinder, 24.0401.4312 SPM valve, 58.0001.12 filter |
Reference: GEBAR (Service and equipment of rail vehicles)
"GEBAR general partnership certifies that CPP PREMA SA has been supplying us with G3/4 compressed air preparation units for over a dozen years, and additionally (for a year) G2 air lubricators. Deliveries are carried out in a timely manner, and the quality of the equipment is flawless. PREMA employees provide assistance and comprehensive technical information about their products."
Modernisation and restoration of older systems
Many systems operate for years, and some components are no longer manufactured or have non-standard installation dimensions. A simple catalogue replacement is then often impossible without rebuilding the system. We manufacture a replacement that is functionally, dimensionally and mounting-compatible - without interference with the entire installation.
System analysis
We check photos, drawings, the pneumatic diagram, mounting method and component function.
Replacement assessment
Catalogue product, adaptation or custom component - we define what is possible.
Solution selection
A component matched to the function, operating conditions, mounting method and service requirements.
Production and support
Component manufacturing, implementation support and further service assistance.
Do you have a component with no available replacement?
Send us a photo, dimensions, markings or a diagram. We will check whether a replacement, repair kit or custom component can be prepared.
Send a technical enquiryHow to select a pneumatic component for a railway application?
We start selection with the function of the system, not only with the thread size. The same valve may operate differently in a wagon hatch, a track machine and an auxiliary module.
- Component function Control, movement, filtration, locking, position holding or mechanism protection.
- Medium and working pressure Installation parameters or a photo of the nameplate of the existing component.
- Operating conditions Installation location, temperature, moisture, dust, vibration and service access.
- Mounting method Plate, hole spacing, ports, stroke and installation geometry.
- Safety Behaviour after pressure loss or signal loss - important for hatches and assemblies.
- Service Repair kit, regeneration option and downtime reduction.
Glossary - railway pneumatics
Sub-base mounted valve
A valve mounted on a common connection plate; in railway applications often used in a G1/2 version to simplify servicing and replacement.
FALNS / FALS wagon
Self-discharging wagons for bulk materials, with pneumatic control of discharge hatches.
Control panel
A panel for operating pneumatic functions of a wagon or machine, combining valves, logic and signalling.
Filter-regulator
An air preparation component combining filtration with working pressure reduction.
Replacement component
A component recreated to be functionally, dimensionally and mounting-compatible with the original, without rebuilding the system.
Repair kit
A set of wear parts such as seals and moving elements for regenerating a cylinder or valve.
Why CPP PREMA in railway applications?
Certificates and railway qualifications
ISO 9001:2015 (TÜV), certificate of the Rail Vehicles Institute “TABOR” and CNTK qualification certificate accepted by the German Federal Railway Authority (Eisenbahn-Bundesamt).
The largest Polish manufacturer of pneumatics
Over 40 years of experience, production in Poland and our own machine park. CPP PREMA pneumatic control installations have been operating in wagons since 1995.
Custom designs and replacement components
Components adapted to the installation and replacements for discontinued parts - functionally and mounting-compatible.
Pneumatics and hydraulics in one place
In railway applications, both systems often operate together - we support both technical areas and service requirements.
FAQ - pneumatics for the railway industry
What is pneumatics for the railway industry?
It includes components that use compressed air to actuate, control, lock and secure functions in rail vehicles and railway machines - pneumatic cylinders, valves, solenoid valves, filters, control panels and air preparation systems.
What pneumatic products does CPP PREMA offer for railway applications?
Pneumatic cylinders, directional control valves, solenoid valves, filters and filter-regulators, check valves, control panels and control boxes, as well as custom components and replacements for system modernisation.
Does CPP PREMA manufacture replacements for discontinued components?
Yes. We manufacture a replacement that is functionally, dimensionally and mounting-compatible with the existing component, without rebuilding the entire system - especially for valves, solenoid valves and cylinders mounted on existing plates.
For which railway vehicles and machines do you select pneumatic components?
For FALNS and FALS self-discharging wagons, track machines, maintenance and rescue trains, and auxiliary systems - based on documentation, a photo or a sample component.
Do you have railway certificates and qualifications?
Yes. CPP PREMA has an ISO 9001:2015 quality management system certified by TÜV, a certificate from the Rail Vehicles Institute “TABOR” and a CNTK qualification certificate accepted by the German Federal Railway Authority (Eisenbahn-Bundesamt).
What data should be sent for selection or modernisation?
A photo of the component, markings from the body or nameplate, dimensions, pneumatic diagram and information about the vehicle or machine. On this basis, we will assess the possibility of selection or manufacturing.
Ask about pneumatics for the railway industry
Are you looking for a cylinder, valve, solenoid valve, filter, control panel or replacement for an older railway system? Describe the application and send the available data. CPP PREMA will check the possibility of selecting a component, manufacturing a custom part or modernising the system.