The Plasser ScreenLiner 3120 L N Dynamic ballast bed cleaning machine, part of ZRK-DOM’s maintenance fleet, is proving its worth during the renovation of the two main running tracks on the international line from Frankfurt an der Oder eastwards to Warsaw.
0 km
Length of the line
Quality of the ballast bed determines quality of the track
The quality of the ballast bed is crucial for track safety and stability. Track ballast plays an important role, and ballast fouling caused by operations, weather, or lost cargo must be removed regularly.
Ballast bed cleaning creates optimum conditions for track maintenance and stabilizes the track position in the long term. It increases ride comfort, safety, and cost efficiency. If carried out in time, it extends the service life of the track and reduces annual costs.
Poland is modernizing its railway infrastructure sustainably, relying on machines from Plasser & Theurer. Particularly noteworthy is the ScreenLiner 3120 L N Dynamic for ZRK-DOM – the first machine in the new ballast cleaning system series.
Operating staff notes:
The machine works very reliably without any major problems. We had some repairs and minor malfunctions, but overall everything runs smoothly. One clear advantage is that the machine has a DGS (Dynamic Track Stabilizer). After cleaning the ballast, the track is stabilized and the ballast is compacted accordingly. This saves an extra downstream pass. Another important benefit is that the excavating depth and crossfall are maintained, as this machine reliably keeps these parameters constant.
ScreenLiner used successfully right from the start
Because the new cleaning system was delivered last year, ZRK-DOM was able to carry out the planned ballast cleaning according to schedule – much to the delight of the customer, who was able to thoroughly test the new Plasser ScreenLiner 3120 L N Dynamic directly in the field.
The first work with the ScreenLiner took place on the Bieniów – Lubsko section of Line 275, a line that has been revitalized after being decommissioned almost 30 years ago. Work on the Szczecinek–Białogard section of Line 404 followed from October to December.
At the turn of 2024/2025, work began on renovating the two main running tracks of Line 003, which runs between Berlin and Warsaw. Due to considerable wear and tear as well as ballast fouling caused by traffic, a full-scale track renewal is being carried out.
Work began in Warsaw towards the west to Frankfurt on the Oder on the section between Poznań Górczyn and Zbąszyń. It comprises ballast cleaning, including the addition of missing track ballast and the replacement of the overhead contact line over a length of approx. 115 km, with the renewal being done in both directions of travel.
Excellent cleaning and consistent output
In 2025, the machine had cleaned around 40 kilometres of track by November. In total, around 90 km have been cleaned since it went into service in mid-2024. The machine's average output while working so far has been around 160 to 165 m/h, with very slight fluctuations. This indicates stable machine operation. The data comes directly from the machine's control system via the MachineConditionObserver (MCO) portal.
The cleaning performance depends largely on the degree of fouling of the ballast, the capacity of the MFS wagons used in the machine formation, and the distance to the unloading area.
In addition to the Plasser ScreenLiner 3120 L N, ZRK-DOM is using the following machines on the renewed section: a 09-3X Dynamic Tamping Express, a 08-32 universal tamping machine, a DGS-62N Dynamic Track Stabilizer, a USP-2000 C2 ballast profiling machine, a Unimat 08-275 3S universal tamping machine, and several MFS 120 SC material conveyor and hopper units.
A new take on ballast bed cleaning trusted around the globe
Plasser & Theurer cleaning systems ensure efficient, safe needs-based ballast maintenance and thus are conducive to sustainable, low-disruption mobility. The ScreenLiner 3100 series is based on the time-tested RM 80 technology that has won over customers in 40 countries. It embodies an unbeatable combination: precisely cutting the formation over the entire width of the ballast bed and effectively recovering usable ballast together with the new arrangement of the power wagon and the resulting improved ergonomics.
The new series has a modular design: it can be self-propelled or not, in a 6-axle or 8-axle (L) design according to the requirements specification, and with additional optional features such as a new-ballast supply system (N), dynamic track stabilization (Dynamic), and a recording measuring system with the DRP for recording the track geometry and important working parameters.
Equipped for a wide range of applications and work documentation
To meet the requirements of ZRK-DOM, the machine was customized and equipped with additional features and functional enhancements. In addition to the new-ballast supply and recording measuring systems, dynamic track stabilization is already integrated into the cleaning process. The design (L) is approved for travel on lines with an authorized G1 structure gauge (EN 15273) and above or line category C2 (maximum axle load 20 tonnes) and above. Additional parts for the excavating device also allow ballast cleaning in turnouts without removing them.
The track geometry measuring and recording system in conjunction with the DRP Data Recording Processor provides information on key track geometry parameters both during and after ballast bed cleaning. All values relating to work quality and ballast formation are documented and make verification reports more precise.
Everything in view thanks to an ergonomic, clearly laid-out work cab design
Operating staff were particularly impressed with the machine’s modern design, its high functionality, and its ergonomics. The work and social cabs are sound-, heat-, and vibration-insulated and provide safe working conditions. Camera systems provide an optimum view of the excavating chain and lifting unit as well as the ballasting unit, screening unit, new-ballast supply system, and the areas in front of and behind the machine. As the first months of operation were in autumn and winter, the operating team were very pleased to have the crew area.
Advantages for cost efficiency, eco-friendliness, and logistics
The machine works together with nine MFS 120 SC material conveyor and hopper units. On the one hand, these can collect all the spoil from the ballast bed cleaning and, as a further function, supply the machine with new ballast. Therefore, material logistics are handled in a track-bound manner. This saves several lorry runs, the construction of access roads is not necessary, and it protects the environment.
With the current spoil volume, the material conveyor and hopper units are only used for spoil transport in order to keep the machine's output high. Additional material conveyor and hopper units are required to also be able to provide new ballast at the same time. This simplifies worksite logistics and increases efficient use of track possessions.
Fully committed to Poland's railway network
In October 2025, the machine completed two weeks of continuous operation (two shifts, day and night) on the line between Zbąszyń and Poznań, satisifying everyone involved. On this construction section, 15 kilometres of track were cleaned at an average working speed of around 150 m/h.
After the work was completed, the ScreenLiner was brought to the ZRK DOM base for maintenance. Regular maintenance ensures that the machine can continue to be used reliably in various regions of Poland in the future. Doing so develops the infrastructure further and ensures rail transport safety.
Project data
| Project description | Ballast bed cleaning on a main line |
| Country of operation | Poland |
| Length of the line | 115 km, two tracks |
| Company | ZRK-DOM |
| Infrastructure manager | PKP Polskie Linie Kolejowe S.A. (PKP PLK) |
| Machines in operation | Plasser ScreenLiner 3120 L N Dynamic |
| Field of application | |
| Working mode |
Map
