Australia is committed to a target of net zero greenhouse gas emissions by 2050, and the rail industry has a major role to play.
The transport sector is currently the country’s third largest emitter, with 60 per cent of those emissions coming from cars and light commercial vehicles alone.
A major mode shift will be key to a greener future – with more passengers and freight on rail rather than roads.
But the rail industry’s role in decarbonisation doesn’t stop there, with companies increasingly turning to solutions such as recycled materials.
Australian owned and operated business Salix is a leader in this field.
In 2022, Salix launched its green range, a selection of innovative low carbon and sustainable products for the rail market.
A highlight from the range is the Infinity Composite Sleeper, a next-generation sleeper that is made from 100 per cent recycled mixed plastics – mostly household waste – and is fully compostable.
Developed in 2015 by Pioonier, Salix is the exclusive licensed partner for Australia and New Zealand.
It is the only sleeper in the world made entirely from 100 per cent post-consumer plastic waste, helping eliminate a major landfill problem. It is processed and reinforced through a patented manufacturing method that guarantees consistency. The system is also a fully closed-loop, meaning that once the sleeper reaches the end of its life, it can be recycled to create a new one.
With carbon dioxide savings of 300 kilograms per sleeper and landfill reduction of 113 tonnes per kilometre of track, the Infinity Composite Sleeper is a sustainable choice.
The product can also be designed to any network specifications, from passenger rail to freight and heavy haul.
It’s not just suitable for mainline rail but also for turnouts and bridges, and it comes with a lifespan of up to 50 years – saving operators time and money on maintenance and replacements.
The Infinity Composite Sleeper has been successfully used across multiple rail networks around the world. It has demonstrated outstanding performance in rigorous testing, including a three-point bending test, dynamic track test in ballast, and thermal expansion assessments. The sleepers are already certified in Europe and by MXV. They meet – and exceed — the standards of the American Railway Engineering and Maintenance-of-Way Association (AREMA).
MXV granted its seal of approval after conducting wear and abrasion tests at temperatures as low as minus 40 degrees Celsius. The sleepers also withstood testing at 60 degrees Celsius for 3,750,000 cycles at 35 tonnes per axle.
Tested to 37.5-tonne axle loads and speeds of up to 160 kilometres per hour, the sleepers have proven to be both durable and high-performing. Additionally, the Infinity Composite Sleeper can be used with any fastening system, is fully customisable and can be installed with ease.
The Infinity Composite Sleepers are built to withstand all climates, from Melbourne’s cold winters to Perth’s scorching summers. They are currently being installed across multiple networks in Australia and New Zealand, with type approval processes still underway.
Silvana Kinninmont, Sales Manager at Salix, said Infinity Composite Sleepers have proven to be a “game-changer”.
“They offer the strength and durability we need, while delivering long-term savings in both maintenance and replacement. It’s a smarter, more sustainable solution that helps us future-proof our networks.”
To make the sleepers, recycled plastics are processed under a patented manufacturing process to guarantee consistency.
“With wooden railway sleepers, early decay can lead to premature failures, and there are limited end-of-life solutions for the sleepers,” Kinninmont explained.
“The Infinity Composite Sleepers are a circular economy solution to these premature failures.”
The Infinity Composite Sleeper also reduces noise and vibrations when compared to alternatives.
Senior Manager Sushil Jain said the sleepers allow Salix’s clients to meet their performance needs while maintaining a positive environmental impact.
“Infinity Composite Sleepers give our clients real peace of mind,” he said. “They reduce waste, extend asset cycles, and help rail operators move towards more sustainable infrastructure.
“Plus they’re reliable, easy to work with, and deliver long-term value by reducing maintenance needs.
Composite sleepers last significantly longer and in many cases outperform alternatives in demanding environments.
Fewer replacements mean lower renewal costs and less disruption to operations, which means a more advantageous total coast of ownership (TCOO).
“At the end of the day, it means safer, more cost-effective rail networks for our customers.”
