A New Phase in Freight Maintenance In The DAC Era: Data-Driven, Borderless, Real-Time

Building Smarter Inspection Regimes, Retrofitting Aging Wagons, And Unlocking ROI From DAC, CBM, And Cross-Border Upgrades

We’d like to thank the European rail freight industry for investing the time to help shape this agenda.

→ This isn’t a theoretical agenda—it’s been co-built with the operators tackling these issues daily, 

     ensuring the right conversations happen with the right people in the room.

You’ve shared some very valuable insights, and we're genuinely grateful. It's clear—from initiatives like DAC to broader maintenance challenges—that we're entering a new phase. One where condition-based maintenance, real-time diagnostics, and improved cross-border coordination are no longer optional, but essential.

→ The agenda doesn’t just reflect these trends—it’s packed with operator-led sessions on DAC 

      readiness, CBM deployment, and real-world use cases of scalable digital diagnostics.

“It’s Never Been Done Properly”—So Now We’re Doing It
 

At the heart of all this is freight rolling stock maintenance, reliability, and upgrading. And yet, there’s never been a truly dedicated event. Sure, one or two breakouts at larger trade shows may touch on freight maintenance—but in your own words, it's never been done properly. With so many challenges and transitions on the horizon, there’s never been a more important time to share knowledge and collaborate.

→ That’s why we’ve made sure the entire programme is focused on solutions: alert handling, digital 

     retrofits, bogie health, depot readiness, and more—no generic content, just freight-specific impact.

→ That’s why each session links directly to implementation: we’ll cover cost-per-wagon retrofit 

      strategies, DAC-enabled alert workflows, predictive tech adoption, and low-friction 

      depot integration.

→ Freight Day will tackle DAC from all sides—retrofitting, diagnostics, bogie integration, IT 

      architecture, cross-border fitment, and workforce readiness.

→ We’ll cover exactly what DAC enables—from brake pad alerts to wagon ID and telemetry—and how 

      to prepare for maintenance model shifts it will force across Europe.

Driven by EU mandates, DAC is now a key investment priority. But operators aren’t just being asked to buy into the vision—they’re also being asked to demonstrate real operational value: better availability, higher safety, and meaningful maintenance savings. That’s why DAC sits squarely within the maintenance conversation.

→ That’s why our DAC sessions include early ROI data, case studies from pilot operators, and 

     strategies for building internal buy-in and workforce confidence.

We’ll be bringing in operators to share DAC pilot deployments, including early predictive use cases. Think: brake pad wear estimation via DAC stream data, or using DAC for bogie and brake health diagnostics. There’s a growing portfolio of pilots and case studies already underway.

→ These use cases will be front and centre across sessions: what was trialled, what worked, and 

     how alerts are being used to reduce failures, downtime, and manual checks.

→ Our sessions will cover adoption roadmaps, readiness assessments, and lessons from early 

     adopters to help operators decide when and how to scale DAC retrofits.

→ Dedicated panels will break down DAC alert logic, actionable thresholds, alert triage models, and 

     what real predictive maintenance looks like at wagon level.

Connecting Use Cases to Availability: The New Freight Equation
 

We’ll have big-picture discussions around use cases like brake diagnostics, wheel and lifecycle tracking, and failure mode detection. All of this is happening at a time when freight operators are under pressure to improve availability and stay competitive. Performance must be robust, availability high, and costs controlled.

→ These sessions won’t just highlight use cases—they’ll map how they’re being rolled out, what 

      infrastructure or workforce adjustments are required, and how they impact cost-per-km.

We’ll spotlight predictive maintenance algorithms already showing a 20–30% reduction in unplanned downtime. That’s real money. Some operators are achieving this using analytics-based approaches—RFID, GPS, and onboard diagnostics for key freight assets.

→ Expect detailed walkthroughs of how operators achieved those results—what data sources they 

      used, what tools they deployed, and how they overcame resistance in the field.

Of course, the journey toward CBM and predictive maintenance isn’t without its challenges. One recurring theme you've raised: IoT sensor errors—particularly on long wagons—can be costly and frustrating. That needs real-world solutions, not theory.

→ These sessions will focus on engineering-level fault tolerance, vendor calibration processes, and 

      operator experiences where false positives or failed sensors derailed early trust.

Harmonisation and Hybrid

Alongside the digital conversation, we’ll also tackle harmonization. Just like in the passenger world, freight operators increasingly see the value of hybrid traction—whether that’s batteries or other energy strategies for specific segments of the journey. We’ll examine the retrofit and maintenance implications of these shifts too.

→ Sessions will cover hybrid retrofit programmes, cross-border compatibility, and maintenance 

     strategy adjustments when battery or energy-hybrid wagons enter service.

We’ll ask: how can maintenance strategies work across borders? How do you align inspection intervals between countries? When does predictive maintenance actually pay off in a low-margin business like freight? And where is condition-based monitoring “good enough”?

→ These topics are baked into our strategic sessions, with real-world benchmarking from cross-

     border operators sharing how they’re adjusting inspection strategies to unlock availability and 

     reduce manual effort.

All of that links to the wider KPI conversation—freight availability, resilience, and cost.

→  Throughout the event, you’ll hear how different operators are tying their maintenance strategy 

      directly to cost-per-km, service failure rates, and downtime metrics that matter to regulators and 

      customers alike.

And we won’t ignore one critical blind spot: ETCS retrofit readiness. This also needs to be factored in at the same time.

→ A dedicated ETCS freight session will unpack what retrofit readiness actually looks like, how to 

     manage the cab-to-track interface, and how freight depots can prepare for mixed fleet scenarios.

So yes—there’s a lot to discuss.

We’re working hard to curate a high-value two-day programme. Each day is separately bookable. Day One (12th November) will be depot-oriented. Day Two (13th November) will take a more strategic focus—still covering DAC, CBM, and predictive maintenance, but with greater emphasis on ROI and when it truly pays off.

→ Each day has been designed to balance tactical execution (Depot Day) and long-term decision-making (Strategy Day), with operators from across Europe sharing grounded lessons, not just slides.For the past five years, the Depot Innovation Day has run as a standalone third day—practical, operations-led, and typically focused on Heads of Depot. It served a clear purpose and delivered value.

But the picture has changed.

In conversations across both passenger and freight, the message is consistent: the depot is no longer just an operational touchpoint—it’s become the pressure point where predictive, digital, and retrofit strategies either land… or stall.

Whether it's data from condition monitoring not being actioned, ETCS retrofits creating delays, or CBM regimes clashing with legacy routines—it’s the depot where these things get stuck. Or solved.

What we’ll explore and unpack

• How predictive and CBM strategies are being reshaped around depot constraints and enablers
• How ETCS and retrofit programmes are being reworked for depot-driven execution
• Why the new two-day structure gives both passenger and freight operators space to address core and depot-specific issues with equal depth
• How do you prove ROI on a CBM programme?
• How do you make hybrid maintenance regimes work across rolling stock types?
• How do you make room for digital upgrades without overloading your existing routines?

Solutions we’ll interrogate through case studies and working sessions:

• Calibrating maintenance approaches (predictive, time-based, condition-based) inside one depot workflow
• Structuring ROI logic around depot execution and availability gains
• Identifying where to modernise vs where to hold back
• Designing depot layouts and digital systems that reflect real traction diversity

Freight Depot Focus: Making DAC, Predictive and Interoperability Real

Freight depots are now on the hook for more than just throughput—they’re expected to deliver DAC diagnostics, firmware upgrades, sensor integrity checks, and alignment with European interoperability standards.

But as several of you said plainly: “Without depot readiness, DAC is just expensive hardware.”

Freight depots that haven’t modernised are already falling behind. And it’s not just about avoiding non-compliance—it’s about protecting corridor performance, interoperability, and commercial viability.

Freight depot solutions being unpacked

• How DAC-enabled depots are structuring diagnostic, firmware and inspection workflows
• Where freight operators are succeeding in condition-based triage and maintenance planning
• Strategies for harmonising inspection routines across European partners
• Practical changes to depot layouts and shift roles to support predictive execution
• How to embed alert-driven workflows without overwhelming depot resources

Future Freight Depot: Rethinking Skills, Systems, and Schedules

Beyond systems and infrastructure, you’ve made it clear: freight depots are facing people challenges.

Skilled labour is scarce. Legacy routines dominate. And retrofitting a depot—either physically or operationally—isn’t a paint-by-numbers exercise.

The next-generation depot needs people who can interpret data, calibrate sensors, action alerts, and manage multi-vendor retrofits on rolling stock that may be cross-border tomorrow.

Solutions discussed during the depot workforce stream

• How leading operators are building technical roles around DAC, diagnostics, and firmware readiness
• What works (and doesn’t) in training staff to trust, interpret, and respond to digital alerts
• New approaches to shift structures, multidisciplinary teams, and triage roles
• Lessons in building technician confidence in CBM and DAC tasks—without overwhelming themNearly every regional and mainline operator we’ve spoken to—bar one or two outliers—is grappling with ageing fleets. Many metro networks are under growing financial pressure, making cost control non-negotiable. And although we’re now nearly three years beyond the height of COVID, the challenge of attracting passengers back to commuter and regional services is still very real. The result? Operators are being asked to deliver more—often with less.

Regional operators in particular are more exposed: they tend to run older rolling stock, cover less-electrified or semi-rural corridors, and face tighter margins. These constraints make investment prioritisation, asset sweating, and incremental innovation all the more critical.

Join us as we dissect:

• How operators are justifying retrofit budgets in financially constrained environments
• Which funding mechanisms (e.g. EU recovery funds, sustainability-linked grants) are being tapped most effectively
• Practical tools for asset tracking, digital monitoring, and prioritising interventions on aging fleets

Why “One Size Fits All” Doesn’t Work for Regional Rail/Metro

While high-speed and mainline case studies are interesting, regional operators have told us they need content that reflects their reality: shorter trains, frequent stops and turnarounds, tight and irregular depot access, and mixed-age fleets. Your operational pressure points are different—and that’s why we’re focused on putting more regional  and metro case studies front and centre this year.

When these nuances are overlooked, the results can be inefficient maintenance strategies, low ROI on digital tools, or worse—negative passenger experiences. This year’s programme directly tackles those variations.

A closer look at:

• How operators are adapting CBM and alert workflows to dense turnaround and depot schedules
• Lessons in balancing modular tech rollouts with mixed fleet constraints
• Frameworks for tailoring predictive tools to low-footprint or decentralised operations

Why Regional Operations Are a Different Game

On our dedicated passenger day, nearly 45% of presentations are drawn directly from regional and metro operators. These operators face distinct challenges, especially around high-frequency depot access. If you're running condition-based regimes and responding to real-time alerts, everything must align seamlessly. One misstep risks disrupting service and causing reputational damage.

We’ll break down: 

• How predictive maintenance is being safely integrated into real-time regional operations
• What depot processes and governance frameworks support live alert response
• How different operators structure shift patterns and access plans to support high-frequency demands

Life Extension vs Replacement: The New Economics of Fleet Management

For newer fleets, we’ll explore how predictive data can identify short-notice maintenance windows and optimise interventions. But the bigger conversation is life extension. How do you maximise the value of 20–40-year-old EMUs, DMUs, and metro cars?

Where does CBM genuinely pay off? What’s the tipping point between overhaul and replacement? And how can modular digital tools extend lifespan without triggering a full-scale rebuild? You’ll hear from operators who’ve made it work—such as those in Scandinavia and southern Germany—where long-term planning meets lean investment.

Sessions will unpack:

• How to evaluate overhaul vs. retrofit vs.replacement using real-world TCO data
• Digital and mechanical interventions that extend fleet life without fleet-wide system change
• What combinations of condition-monitoring and tactical upgrades have proved most cost-effective

How Fleets Are Scaling Modularity Without the CapEx Burden

Modularity is fast becoming a strategic lever for regional operators. You see the value in scaling CBM, but want to avoid the cost and disruption of deep integration. Some operators are already proving it can be done—using modular CBM kits for things like wheel sensors, brake monitoring, and HVAC diagnostics.

This year, we’ll unpack specific use cases from operators in Austria and the Netherlands who’ve adopted modular approaches at scale.

What You’ll Learn in the Agenda:

• What “plug-and-play” really looks like for core rolling stock subsystems
• Integration paths for modular condition-monitoring and retrofits on legacy trains
• How to structure procurement to fit modular technology within OpEx constraints

How to Build Digital Confidence on a Shoestring

We know large-scale training budgets aren’t realistic for many regional networks. But upskilling is still critical—and it’s not an HR issue. It’s an operational engineering one. Getting frontline teams to trust diagnostics, act on alerts, and use mobile tools requires design thinking, intuitive platforms, and confidence built over time.

It’s not just about skills—it’s about belief. That the tools are accurate. That alerts matter. That data is actionable. This year, we’re moving beyond the problem and showcasing solutions that build digital fluency within real workforce constraints.

Make sense of: 

• How frontline staff are learning to trust and act on predictive alerts
• Design features and workflows that increase digital tool adoption without extensive retraining
• The difference between tech rollout and true cultural integration—and how to close that gap

Lessons from ETCS Readiness: Change People Want to Join

There’s strong crossover here with our recent ETCS event, where we saw operators succeed by building buy-in—not through mandates, but through behavioural nudges, simulation, and peer-led adoption. Some used depot simulation environments. Others used storytelling and internal champions.

The goal: not just adoption, but genuine engagement. These same tools are being applied now to CBM rollouts, retrofit platforms, and mobile diagnostics across regional fleets. We’ll bring those cross-sector insights to the stage.

See real-world examples of:

• How change leaders across sectors earned workforce trust in complex rollouts
• Practical use of simulation, peer learning andearly wins to unlock wider buy-in
• Frameworks for managing workforce transitions across digital and mechanical systems

Tools That Fit the Train—and the Budget

Operators told us clearly: retrofit-focused, modular tools are the future. Think door diagnostics, HVAC sensors, and mobile apps that simplify inspections, task sign-off, and part ordering. 

Done right, they deliver high ROI and workforce traction—even when deployed incrementally. You’ll hear examples from UK, Nordic, and central European operators who’ve proven this model at scale.

Expect practical case studies on:

• Real-world retrofit examples that delivered ROI without system overhauls
• What makes a retrofit tool genuinely “technician-ready” and interoperable
• How mobile-first solutions are transforming regional maintenance workflows

Why Frankfurt Unlocks Access for Regional Rail

We’ve chosen Frankfurt strategically—to tap into the vast regional and metro operator market across Germany, Austria, the Netherlands, and Central Europe. Many of these operators don’t typically attend UK-based events. Frankfurt provides fast rail links, minimal friction, and high peer-relevance.

Expect meaningful benchmarking, shared learnings, and operator-to-operator insights—without the airfare. It’s a rare opportunity to network with peers who face your challenges, speak your language, and share your maintenance pressures.