Alstom opens new state-of-the-art plant 4 facility in Hornell, NY, boosting U.S. rail manufacturing

• Plant 4 reshores Alstom’s stainless steel car body shell production to the U.S. and solidifies Hornell’s status as the country’s largest passenger train manufacturing site and the Southern Tier of New York as the nation’s center of rail excellence
• The first project for the newly opened plant is the production of modern multilevel commuter rail cars for Metra, Chicago’s regional train system
• Alstom has invested $75 Million to build and outfit Plant 4

Alstom, global leader in smart and sustainable mobility, announced the opening of its cutting-edge Plant 4 manufacturing facility in Hornell, New York. The plant is one of the few advanced manufacturing facilities in the United States capable of producing stainless steel car body shells for passenger rail vehicles. 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 centre of rail excellence. It will also strengthen domestic supply chains for the U.S. rail industry. 

The high-tech facility, which is set to begin production on 200 multilevel commuter rail cars for Chicago’s Metra system, marks the latest chapter in Alstom’s ongoing commitment to American manufacturing excellence and to creating high-quality jobs in New York’s Southern Tier.

“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.”

Empire State Development President, CEO & Commissioner Hope Knight said, “Alstom’s ongoing commitment to expanding its operations and advancing rail technology will keep Hornell, and the entire region, on track for continued economic growth. Advanced manufacturing is a critical Upstate industry, and we are grateful to Alstom for its dedication in reshoring the company’s car body shell production to the United States and for creating solid job opportunities right here in the Southern Tier.”

“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. The opening of Plant 4 today 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,” said Senator Schumer. “Today, Alstom solidifies the Southern Tier and New York State as the beating heart for its North American operations. I’ve long fought to support Alstom’s growth in Steuben County and will continue to fight to ensure Hornell has the resources it needs to be one of the nation’s main hubs for rolling stock manufacturing.”

Congressman Nick Langworthy said, “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. 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.”

Hornell Mayor John Buckley said, “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. 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. This collaboration strengthens Hornell’s position as a leader in transportation innovation and manufacturing. We are deeply grateful to Governor Hochul and Alstom for their ongoing support and commitment to our community’s future.”

Southern Tier Regional Economic Development Council Co-Chairs Judy McKinney-Cherry, Executive Director of SCOPED, Inc., and SUNY Delhi President Dr. Mary Bonderoff said, “This project has indeed proven to be a win-win for the Southern Tier and all of New York State. Thanks to the Governor’s leadership, we are making transformative investments in leading industries and improving our transportation equipment manufacturing network for the 21^st century, ensuring that the region with continue to soar for years to come.”

“The IAM Union could not be more proud to represent the dedicated and skilled workforce at Alstom,” said IAM Union International President Brian Bryant. “IAM Union members right here in Hornell, New York are building the future of rail transportation in the United States and beyond. These are generational, family-sustaining union careers that benefit the entire community. We look forward to continuing this important work with Governor Hochul, Alstom, and our state and local partners to grow this workforce and the entire U.S. rail industry.”

Alstom invested $75 million and worked with 40 contractors to build and outfit its Plant 4 facility. 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 (EDA), 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. 

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. 

This expansion at Alstom’s Hornell site is expected to create 258 new jobs, including those in mechatronics engineering and robotics-related fields, while helping to retain 390 existing jobs.

Plant 4 is dedicated to the late James W. Griffin, former Executive Director of the City of Hornell Industrial Development Agency. Mr. Griffin fought for Hornell’s status as a national center of rail excellence and for the rail industry as a vital job creator for the region.

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