PARTNER CONTENT
This content was produced by Automotive Logistics in partnership with Helrom.
Helrom is redefining supply chain logistics with an innovative intermodal system that slashes emissions and improves efficiency.
Rail technology specialist Helrom is making a sustainable shift in supply chain logistics through its Block Train project for Audi, in collaboration with logistics provider Duvenbeck. By integrating road and rail transport seamlessly, the initiative is not just reducing emissions but also improving supply chain efficiency and resilience.
Helrom’s Block Train project is breaking new ground for automotive logistics, by making it possible to load all types of truck semi-trailers onto a train without any special terminals and cranes.
The Block Train project for Audi, which runs between Regensburg and Lébény in Hungary, is the first realisation of barrier-free rail transport of truck semi-trailers. Each train consists of 18 wagons that can transport 36 trailers, travelling 1,000km per round trip in just 24 hours. This means that 72 trucks are shifted from road to rail every day from Monday to Friday, including loading and unloading time, resulting in a weekly reduction in truck transport performance of around 185,000km.
Read more: Audi’s Dieter Braun on the OEM’s partnership with Helrom
“With our innovative technology, we are overcoming the barriers of previous intermodal transport,” said Roman Noack, CEO of Helrom. “By eliminating the need for special terminals for loading semi-trailers, we are integrating ourselves smarter into supply chains.”
He added: “Audi believed in this solution as a pioneer and proved that it is possible to combine environmentally friendly technologies with economic interests. This project shows how important it is for the future to give new concepts a real chance.”
Noack said the Block Train is faster and more reliable than previous intermodal transport. “The efficient networking of different technologies and transport routes such as road and rail to form a physical internet of semi-trailers via Helrom hubs as smart interfaces is key to achieving climate targets in freight transport.”
Digitally integrated and efficient transport
The Block Train concept brings together more than 50 suppliers across multiple European locations, optimising material flow for Audi’s production network. The core innovation lies in the seamless loading of truck trailers onto rail without specialised terminals, allowing a smooth transition between modes of transport.
The globally patented Helrom trailer wagon is a fast, simple and flexible way to transport all types of truck trailers over long distances by rail. To load, the trailer is decoupled from the tractor, the Helrom trailer wagon opens up at the side, the trailer is shifted on the wagon and the wagon is reclosed. Once it reaches its destination, it’s unloaded in the same way.
No expensive loading terminals, cranes or craneable semi-trailers are needed – just a level ground next to the train track is required. Helrom guarantees it can get 100% of all truck trailers onto the tracks without any major outlay.
“Our goal is to harmonise economics, ecology and social sustainability,” – Dieter Braun, head of supply chain, Audi
Bruno Weissmann, director of sales at Helrom said: “Helrom trailer hubs can be set up anywhere where there is a track with an asphalted surface and a car park. We are really taking the combination of truck and rail to where it is needed.”
This flexibility has enabled the Audi to reduce reliance on long-haul road freight while maintaining just-in-time (JIT) and just-in-sequence (JIS) deliveries.
Comprehensive digital integration of all elements of the transport chain ensures a previously unattainable level of precision and reliability. Every single material transport can be digitally tracked from the supplier to production.
A solution to road freight challenges
The project directly addresses two critical challenges in the automotive logistics sector: rising carbon emissions and a worsening shortage of truck drivers. By shifting transport to rail, Audi has cut more than 185,000 road km per week, leading to an annual CO2e reduction of 11,500 tonnes.
Meanwhile, shorter road journeys in the first and last mile have improved working conditions for truck drivers, providing better planning security and work-life balance.
But Helrom’s Noack stressed that rail and road logistics firms do not need to be direct competitors, and instead can choose to work together on intermodal solutions that benefit everyone.
“The freight forwarder Duvenbeck has played a key role in this, both in linking road and rail, and in managing the supply chain,” Noack said. “Together, we have proven that these two modes of transport are not competitors, but strong allies for a sustainable transformation of freight transport.”
Rail as a viable alternative
Rail transport is widely recognised as an efficient and eco-friendly alternative to road freight, yet challenges such as inflexible infrastructure and unreliable service quality have hindered adoption.
“Intermodal is more than technology – it’s a team effort,” – Roman Noack, CEO, Helrom
The Helrom trailer wagon overcomes those barriers by allowing truck trailers to be loaded onto rail in just two minutes, without cranes or special terminals. Combined with Duvenbeck’s central logistics management, the system ensures precision timing and supply chain visibility through real-time digital tracking.
A blueprint for sustainable supply chains
With the ability to transport 360 truck trailers per week in five round trips, and deliver to four Audi plants across Europe, the Block Train project demonstrates the feasibility of large-scale, decarbonised logistics.
Dieter Braun, head of supply chain at Audi said that improving sustainability while optimising supply chain networks is central to the OEM’s goals. “Consistent decarbonisation is one of our central challenges in the supply chain,” he said. “At Audi, we are pursuing a holistic approach to optimising the logistics processes between our suppliers and our plants. This project shows that we are also integrating innovative and climate-friendly solutions from partners in our supply chain.”
This success provides a model for other OEMs looking to enhance supply chain resilience while meeting sustainability targets.
Key achievements:
- 99% delivery reliability across the network
- 5% improvement in lead times compared to road transport
- 25% reduction in lead time overruns, ensuring greater consistency
- Road km reduced by 185,000 per week
- CO2e reduction of 11,500 tonnes annually
The future of automotive logistics
Helrom’s Block Train initiative is more than an efficiency-driven project; it represents a shift in how automotive supply chains can operate sustainably.
By leveraging digital integration, intermodal transport, and collaboration between key logistics players, the project sets a precedent for the broader industry.
As the automotive sector pushes towards net-zero targets, Helrom’s approach showcases how sustainable logistics can drive both environmental and economic benefits.
For more information about Helrom and its Block Train, visit Helrom’s website.
No comments yet