Railways have long been a part of Sicilian entrepreneur Giovanni De Lisi's life. The 39-year-old started at a young age, working for his family's maintenance company, De Lisi Costruzioni Ferroviarie. There, he observed problems associated with traditional railroad ties, called sleepers, which are made of concrete and subject to high wear and environmental impact. Giovanni investigated the potential of using recycled materials, such as plastic and rubber from used tires. That led him to found Greenrail Group in 2012, with offices in Milan and Rome.
"The goal was to create a more innovative, sustainable, and high-performance railway sleeper," says Giovani, who divides his time between Palermo and Milan.
We recently corresponded via email, during which he shared Greenrail's innovations and benefits, current and upcoming projects, and his optimism for the future of smart technology in the railway industry.
Can you explain how Greenrail's smart sleeper technology works?
The Greenrail railway sleeper is an innovative sleeper designed to combine sustainability, efficiency, and durability. This railway sleeper is a combination of traditional and recycled materials, aimed at enhancing performance and reducing environmental impact.
Key technical features:
- Hybrid structure: The inner part is made of reinforced concrete, ensuring the structural strength and stability of the sleeper. The outer coating consists of a mixture of recycled rubber and plastic obtained from used tires and other plastic waste, thereby reducing the need for virgin raw materials and contributing to recycling.
- Durability: Thanks to the outer coating made of recycled materials, Greenrail is less prone to wear compared to traditional concrete sleepers. This outer layer protects the internal structure from weather, erosion, and chemical action, extending the lifespan of the sleeper. The estimated lifespan of a Greenrail sleeper is over 50 years, making it a long-lasting solution compared to conventional options.
- Mechanical and vibrational resistance: The mechanical properties of reinforced concrete ensure high resistance to compression and dynamic loads typical of railway lines. The rubber coating acts as a natural shock absorber, reducing vibrations transmitted to the ground and improving the comfort and stability of train passage.
- Electrical insulation: Greenrail provides better electrical insulation compared to conventional sleepers, reducing the risk of electrical leaks and ensuring better operation of electrified railway lines.
- Environmental sustainability: Each individual Greenrail sleeper recovers approximately 35 kilograms of recycled rubber and plastic, reducing waste accumulation. During its lifecycle, it helps reduce CO₂ emissions through the use of recycled materials and increased durability compared to traditional solutions.
- Compatibility: The Greenrail sleeper is designed to be compatible with standard railway technologies and can be installed on existing railway lines without significant modifications to the infrastructure.
- Advanced versions: In addition to the basic version, Greenrail also offers variants such as Greenrail Solar, which integrates photovoltaic modules into the design, allowing for solar energy generation, and Greenrail Linkbox, which integrates sensors to monitor the state of the railway lines.
These features make the Greenrail sleeper a cutting-edge solution in the railway sector. Its strong focus on sustainability and technological innovation revolutionizes its ability to improve safety and reduce operational costs.
What are the key benefits of integrating sensors and solar panels into railway sleepers?
The integrated sensors allow for constant monitoring of the network's status, improving safety and reducing maintenance costs through predictive interventions. Solar panels, on the other hand, generate up to 44 megawatt-hours of energy per kilometer per year, transforming railway infrastructure into sources of renewable energy. This has a significant impact on environmental sustainability and energy efficiency.
How does Greenrail's use of recycled materials contribute to sustainability?
By using recycled plastic and rubber, Greenrail significantly reduces its environmental footprint. Our sleepers reduce CO₂ emissions by 40% and decrease noise, energy consumption, and water usage compared to concrete sleepers. This circular economy not only limits waste but also extends the operational lifespan of the sleepers.
What impact do Greenrail sleepers have on the passenger experience compared to traditional sleepers?
Greenrail sleepers contribute to a reduction in vibrations of up to 40%, ensuring greater comfort for both urban residents and passengers. Additionally, the smart technology will help prevent failures and service interruptions, ensuring greater reliability and safety.
What has the response been?
The response has been extremely positive, both from railway operators and environmentalists. Our pilot projects in Europe have confirmed the effectiveness and sustainability of our solutions. Greenrail Solar, in particular, has attracted a lot of attention for its ability to generate renewable energy, in addition to all the other advantages of Greenrail technology for railway infrastructure.
What are the next steps for Greenrail in terms of market expansion?
We are aiming to expand into international markets, especially in Europe and North America. We have already patented our technology in over 80 countries and plan to build industrial plants to meet demand. Our strategy also includes licensing our technology to local manufacturers, who will use local recycled materials.
How do you see the role of smart technology evolving in the railway industry?
Smart technology will be the future of the railway sector. Predictive maintenance and real-time monitoring will become the norm, improving safety and operational efficiency. I foresee an increasing integration of artificial intelligence and IoT technologies to further optimize infrastructure management and minimize human errors. Our smart sleeper technology is just the beginning.
Are there any projects or collaborations that you are particularly proud of?
One of the most significant projects is the pilot installation of Greenrail Solar in Emilia-Romagna. It was the first concrete example of our solar technology applied in the real world, with very promising results in terms of energy production and durability. We are also proud of the collaborations that are being concretely activated in the short term with some operators of European subway lines to modernize their outdated systems.
What kind of experience do you hope to provide for your clients and partners?
We want to provide an innovative, reliable, and sustainable solution that brings long-term benefits to both our customers and the environment. We guarantee our partners a smooth collaboration process, from design to implementation, with the shared goal of modernizing railway infrastructure. We focus on trust, transparency, and a constant commitment to improvement.
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