Herrenknecht Tunnel Boring Machines (TBMs): Localised and Customised

“We are committed to localizing our tunnel boring machines (TBMs), with 60-70% of components sourced locally. This unique approach, along with our custom designs and refurbishment services, ensures that our machines meet the highest quality standards, offer long-term efficiency and reliability, and are optimized for local geological conditions,” states Manoj Garg, Managing Director, Herrenknecht.

What is the extent of Herrenknecht’s efforts towards localization and refurbishment of its TBMs, currently?

We are raising awareness among the contractor community about our strong commitment to localizing our tunnel boring machines (TBMs) to the extent possible. Currently, we are aiming for around 60 to 70% of the components sourced locally in next 2-3 years, while some critical components still come from Europe. We are proud to be the only company in India making such significant investments in localizing production. No other manufacturer has achieved this level of localization yet.

Another advantage we offer is that we undertake both manufacturing and refurbishment of TBMs. In refurbishment, we don’t simply replace parts; we thoroughly inspect each component to ensure it meets our stringent quality standards. This process may be time-consuming, but it ensures that the equipment operates efficiently for many more projects, which is beneficial not only for the customer but also for the environment.

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Since every strata is different, how much time does it take to study the geology before customizing a TBM?

Tailoring a TBM to meet the specific geological conditions of a project is a detailed process. Typically, we take about 15 days to study the geological conditions of the site. Based on the analysis, we advise the client on the type of machine required (open, closed, or any other from our range of 4 to 5 types), the appropriate diameter, cutter or bearing specifications, and other key aspects. We do not proceed with customization until we fully understand the requirements of the project.

To ensure the machine is ideally suited for the project, we work closely with the customer's engineers, geologists, and project teams. This collaboration helps us gather essential data about the geological conditions and any special project needs. Then we consider the technical aspects of the TBM to be customized. This ensures that it will be designed for optimal performance and reliability. We see ourselves not only as a manufacturer but as a complete solution provider.

The "Herrenknecht Team"

How do you ensure that the machine works efficiently in different conditions?

In tunnel construction, predicting the challenges encountered underground is difficult due to the variation in geological conditions. Each project site is unique, which is why we make sure that each machine is specifically designed for the local geological conditions. For example, a TBM that works in Mumbai may not be effective in Bengaluru or Chennai, as the soil and rock types can vary significantly. Even within Chennai, if there are five different projects, each one may require a machine customized for the job.

When we have to shift a machine from one project to another, we conduct a thorough study of the new site's geological conditions, based on which we make the necessary design adjustments to make the TBM optimized for the new environment. Thus, every machine is customized to address the unique challenges of the projects, ensuring it performs efficiently and reliably.

Additionally, if requested we provide initial commissioning and training for operators. If specialized training is needed, we also offer the same to ensure machine operates smoothly. Also, if required and requested our team stays on-site to provide continuous support and service until completion of the project.

How do you ensure consistent quality and sustainability of your products?

Our team of senior designers work closely with customers throughout the manufacturing process. We conduct regular design reviews during production, ensuring that any errors are identified and corrected early on. Our experts also help in spotting potential issues that may arise during the manufacturing phase, ensuring that the final product meets the highest standards of quality.

Also, Germany based our operations division ensures that we maintain the same quality standards and expertise in production. Our design and project management teams in India work under the guidance of our German experts. Even our supply chain is centralized, which means that any localized part must meet our principal company’s standards and is certified before being used.

Regarding sustainability, we are committed to reducing waste and using eco-friendly materials in our manufacturing processes. For instance, our TBMs are designed with energy efficiency in mind, which helps reduce their environmental impact. Moreover, nowadays we employ adaptive greasing systems that not only save on lubrication costs but also minimize negative environmental effects.

To reduce wastage, all leftover materials from the manufacturing process are used wherever possible. By focusing on the quality of our products and by following eco-friendly practices, we ensure that our machines are not only high-performing but also environmentally responsible.

How do you view the competition from low-cost countries products in the Indian market which is a cost-conscious?

We offer a range of tunneling equipment, conveyors, formwork and specialized service vehicles, our primary focus is the TBM in India. We have recently secured orders for TBMs with a diameter of 15.5 meters, which is nearly the height of a five-storey building. We now plan to build a TBM with a diameter of 16 + meters.

In India, we have the largest market share and are also preferred suppliers for the technical after sales support that we provide, even though customers are getting a lower priced TBM of another brand from competitors, they are choosing us. Our commitment to quality is the reason why our machines continue to perform well even after completing several projects, plus our long-term service commitment.

How do you see the demand for TBMs growing in India?

India will require around €2 billion (Rs 2,000 crore) worth of TBMs and related equipment over the next five years to support its Tunneling infrastructure development. This presents a huge opportunity for both local and international companies to establish operations in India.

India’s tunneling sector is growing rapidly, which will help the TBM industry to evolve, create jobs, and drive innovation. We’ve made significant investments in India because we believe the country’s tunneling infra has a lot of potential for growth.

There’s also been talk of setting up a National Tunneling Center in India; what is your take on this?

It’s a great idea, but it will take time. To establish a National Tunnelling Center, we first need to build local expertise. For example, in India, we have few hundred employees, over the years we have trained our technical engineers through our European experts. Thus, to develop local trainers, we must first train the workforce and make it a continuous cycle of learning, training, and re-learning.