Alstom Significantly Boosts U.S. Rail Manufacturing with New Facility

Alstom has opened its new Plant 4 manufacturing facility in Hornell, NY. The plant is one of the few manufacturing facilities in the U.S. capable of producing stainless steel car body shells for passenger rail vehicles. The facility is set to begin production on 200 multilevel commuter rail cars for Chicago’s Metra. The 135,000-square-feet facility also provides additional capacity and manufacturing capabilities to support other Alstom projects.

Alstom previously manufactured this type of car body shell for U.S. projects at its facility in Brazil. The investment in Plant 4 reshores production in the U.S. and cements Hornell’s position as the largest passenger train manufacturing site in the country and reaffirms the Southern Tier of New York as the nation’s center of rail excellence. It will also strengthen domestic supply chains for the U.S. rail industry.

“When we invest in American manufacturing, we create good jobs that have a ripple effect across the entire region. We’re not just building trains—we are creating opportunities in Hornell and across the country,” said Michael Keroullé, president of Alstom Americas. “Plant 4 upholds our long-standing commitment to making trains in America, and it expands our ability to deliver cutting-edge rail solutions for our customers. We thank Governor Hochul and all our state, local, and federal partners for their support.”

Alstom invested $75 million and worked with 40 contractors to build and outfit Plant 4. The project was supported by grant, job credit, and tax credit programs from federal, state, and local agencies, including the New York Empire State Development, the U.S. Economic Development Administration, City of Hornell Industrial Development Agency, the U.S. Department of Treasury CDFI Fund, U.S. Department of Housing and Urban Development, New York State Electric & Gas, and the U.S. Department of Labor Employment and Training Administration.

“It’s full steam ahead for Plant 4, Alstom’s new Hornell cutting-edge manufacturing facility! I was proud to secure $3.4 million in federal funding to put Alstom on the fast track to expand and house this new manufacturing facility,” said Sen. Chuck Schumer (D-NY). “The opening of Plant 4 is a win-win-win for American manufacturing leadership, the Southern Tier economy, and Alstom’s powerhouse union workforce, getting even stronger with 250 new good-paying jobs.”

“The opening of Alstom’s new Plant 4 is a major win for New York’s Southern Tier. It will retain 390 existing jobs in Hornell while creating 258 new positions for local residents—a powerful boost for the regional economy,” said Rep. Nick Langworthy (R-NY). “I am grateful to Alstom’s strong commitment to Hornell, and the dedicated workforce that gets those trains on the tracks. The Southern Tier is the capital of rail car and train manufacturing, and this investment is a critical next step in continuing this legacy. By investing in our communities and workforce, we’re building a stronger, more resilient future right here at home.”

The car body manufacturing process involves welding together primary parts to create assemblies as long as 80 feet. At Plant 4, automated welding robots will be used to make sure tens of thousands of welds are precise within 1 millimeter. This is made possible by using state-of-the–art AI technology that allows robots to work together safely, efficiently, and accurately. As a result, transit authority customers will benefit from enhanced quality and lower cost of production.

“Hornell has long thrived as a hub for the railroad transportation industry, and our longstanding partnership with Alstom has played a vital role in that success,” said Hornell Mayor John Buckley. “Alstom’s continued investment in our city has not only created high-quality jobs and driven economic growth here in Hornell, but has also delivered substantial benefits to the surrounding communities and the entire region.”