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Process Locomotives are different from standard locomotives in several ways. Process Locomotives are designed and built to be operated and maintained by end users and short line railroads that want 21st century technology and features comparable to, and sometimes exceeding that, found on the new multi-million dollar line locomotives but at a fraction of the price. This includes but is not limited to: high adhesion traction control, EPA emissions certified engines, radio remote control, PLC microprocessor main controller, HMI graphics interface, video event recorder, data event recorder, remote monitoring, etc. There are two basic ideas behind the design of the Process Locomotive. The first is that it should be equipped with features and options that allow the owner to use non-railroad personnel to operate and maintain the unit. This includes the ability to switch large facilities with ease using a crew of one or two people; as well as, to do PM and other most other maintenance with the facility maintenance personnel that would normally be working on process equipment in the plant. The second idea is that it be rugged, highly dependable, and automated for fuel efficiency, safety, and simplicity of operation. This includes offering equipment and features to meet all FRA, OSHA, US EPA, State EPA, and local facility safety and environmental rules and regulations. It includes microprocessor control of the engine and all electrical equipment and controls. It includes a highly corrosion resistant paint system; du Pont IMRON 333. It includes new type "C" line locomotive wheels with new Timken roller bearings. It includes a reinforced frame and ballast to maximum allowable weight. It includes the ability to remote troubleshoot the unit under loaded conditions from factory to any location in the world that has phone service. It includes and option for a "patented" high adhesion traction motor control system that can produce up to 38% adhesion. This is covered by US Patent 6,012,001. Standard locomotives are designed and built for railroads, not end users. Most new locomotives built today are 4,400 HP and up. These are six axle units that are designed for main line service. Many of these new locomotives use AC traction motors with variable frequency drives. These are highly efficient at main line speeds and they are also highly expensive. To build these types of line locomotives requires multi-billion-dollar manufacturers with hundreds of millions of dollars of facilities to construct. The price tag for one unit can be several million dollars. Process Locomotives do not attempt to compete with these type locomotives. There are a few yard switchers and maybe a few dozen road switcher locomotives that are built in the US each year. A new unit in the 1,500- to 2,000 HP range can range from about $1,500,000 to $2,000,000; and that is before you start adding features. Some road switchers are built from older locomotive cores where the trucks, traction motors, frame, and some other components are reconditioned and reused. Technically these are considered "new" locomotives and are advertised as "new" by some re-builders. We refer to a new locomotive built from an older locomotive core as "new/remanufactured". This is to let the buyer know that all of the component parts are not 100% new. Other manufacturer's and rebuilders often charge between $1,000,000 and $1,400,000 for a 1,500 to 2,000 HP unit respectively for their "new" units. With the new EPA regulations on stack emissions the prices on these units will probably go higher in the near future. It is against these new, "new', and "new/remanufactured" road switchers and yard switchers that the Process Locomotives compete. You may say, "I've never heard of a Process Locomotive. Who would buy such a thing?". The answer is: paper mills, feed mills, grain elevators, chemical plants, MSW facilities, glass manufacturers, automobile manufacturers, coal fired power plants, edible oil plants, oil refineries, coal transfer terminals, pet food plants, cement plants, steel mills, aluminum mills, scrap metal operations, port facilities, short line railroads, etc. In short anyone who needs to move large numbers of railcars in a plant, port facility, switch yard, etc. For some references check our photo gallery. You may also ask, "Why do Process Locomotives owners choose it over a standard locomotive?". There are many reasons and every customer has a different set of reasons. Let us look at a few.
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