LUR’s sustainable approach to rail wheel production delivers up to 75% reduction in steelmaking emissions
Lucchini RS Group, part-owner of the joint venture with Unipart, Lucchini Unipart Rail (LUR) has published its Sustainability Report, showcasing a 75% reduction in steelmaking emissions against the global benchmark.
Driven by a circular approach to steel production, 72% of input materials for wheel and axle manufacture at Lucchini RS in Italy are now sourced from recycled components, including 7% recovered directly from wheels.
As one of the most energy-intensive processes in the industry, steel is typically produced by the Basic Oxygen Steelmaking (BOS) process, which uses Blast Furnaces to melt virgin raw materials, such as iron ore. Lucchini RS use an Electric Arc Furnace (EAF), which reduces CO2 emissions by up to 75% when compared to the traditional blast furnace; this process uses electricity to melt down recycled scrap steel, which in turn significantly reduces the need for raw steel and keeps approximately 25,000 tonnes of steel in circulation each year, cutting emissions and reducing reliance on virgin materials. The EAF process reduces CO2 emissions by over 80% compared to the BOS process which is prevalent in many suppliers.
LUR has collaborated with partners across the rail industry who have focused on optimising and repairing components, reducing waste, and extending the life of the wheelset. These efforts further highlight how more durable, longer-lasting wheel steels contribute to lower emissions, fewer maintenance cycles, and more reliable services across the UK rail network. By extending the wheel lifespan carbon emissions linked to wheelset maintenance can be significantly reduced.
Taking that one step further, the company have introduced an advanced steel grade, SUPERLOS®, which was developed by Lucchini RS specifically for rail wheel applications. With SUPERLOS®, the carbon emissions figures fall even further due to the material's durability, toughness, and resistance to rolling contact fatigue (RCF).
Elsewhere in the business, LUR has worked with sustainability professionals, Groundwork, to deepen its understanding of environmental impact and provide customers with detailed emissions data by developing a product-level carbon footprint for its wheels. Building on this work, LUR plans to implement these recommendations and expand its monitoring of emissions across its operations to gain a more comprehensive view of its environmental impact. Alongside this, the company are exploring further ways to reduce emissions across the business in line with their Carbon Reduction Plan.
“Our work across the joint venture shows that sustainability in rail is about more than reducing carbon. It’s about smarter maintenance, circular supply chains, and energy efficiency that will help shape the industry as we move into 2026 and beyond.”
“Last year, we invested £7.5 million into our Manchester and Doncaster sites to expand output and production capacity, strengthening our ability to deliver sustainable, high-quality solutions for the UK rail network.” says Phil Chilton, Managing Director at LUR.
LUR is a joint venture between Lucchini RS and Unipart. The end-to-end expertise, encapsulated in the company’s strapline “From Furnace to Fleet,” spans sustainably manufactured steel in Italy through to fully overhauled wheelsets and bogies delivered to UK depots.
