Innovative Development of the Stationary Suction System ESE S

Deutsche Bahn faces the challenge of regularly maintaining and renovating the Berlin S-Bahn network without significantly disrupting ongoing operations. The solution: the stationary suction system ESE S from RSP. This innovative system was specially developed to precisely suck ballast from individual track segments, enabling efficient renovation of the track network. In this blog post, we provide you with a detailed insight into the development, commissioning, and versatile application possibilities of the ESE S.

The Development Process of the Stationary Suction System ESE S

Tobias Behnke, a development engineer at RSP, explains how the ESE S came about. Since 2020, he has been part of the RSP team and works in the research and development department. This department is responsible for the further and new development of products, with a particular focus on creating a solid database for optimal customer solutions. "When you start at the beginning of the sales process, the customer comes to us with the suction task they want to fulfill, and we provide them with the idea and the concept, so to speak - and in the best case, the entire system to fulfill their suction task," describes Behnke the process.

The Modules of the Stationary Suction System ESE S

The stationary suction system ESE S consists of several specialized modules, each fulfilling important functions:

  • Fan Module: Generates the necessary suction flow.

  • Filter Module: Available in two variants - a 10-foot and a 5-foot container module. The 5-foot module enables side discharge and filling of big packs, while the 10-foot module has flaps for dust emptying under the module.

  • Material Module: Here, the suction material is collected and later discharged. Optionally, a compressor can be installed that supports additional tools such as compressed air devices. A high-pressure system with a 400-liter water supply can also be integrated.

  • Articulated Hose Carrier Module: Contains the articulated hose carrier of the ESE 8. Here, the material is sucked from the track bed.

  • Sleeper Change Module: The most complex module with a conveyor belt for returning the suction material. It is located under the material module and returns the suction material to the track bed.

Challenges and Solutions

The development of the ESE S posed some challenges for the team. The concept of modularity and the implementation as a container solution were particularly demanding. After creating the specifications sheet and confirmation by the engineers, a functional model was built and intensively tested. This testing phase allowed valuable customer feedback to be collected and the product further optimized. A particular challenge was the deviation from the normal suction excavator. The concept of modularity quickly led to container solutions, which were recorded in the specifications sheet and implemented through a functional model. Intensive tests and initial customer opinions flowed into the final version of the ESE S.

First Commissioning and Handover to the Customer

After successful development and testing, the first ESE S system was handed over to Deutsche Bahn in 2024. The commissioning went smoothly, and the first customer reactions were consistently positive. Thanks to the precise suction of ballast from individual track segments, the renovation of the Berlin S-Bahn network can be carried out without permanent track closures. These works are carried out in blocks, for example, overnight within 3-4 hours.

Application Possibilities of the Stationary Suction System ESE S

The ESE S can be used in various industries:

  • Track bed renovation

  • Tunnel maintenance

  • Industrial applications

  • Decommissioning of industrial plants

Thanks to its modular design and precise functionality, the stationary suction system ESE S offers our customers numerous advantages and high utility. We plan the system together with you for your specific application.


The ESE S represents a significant innovation in the world of suction systems. The development and implementation of this project demonstrate RSP's commitment and expertise in developing high-quality products. The ability to efficiently renovate the Berlin S-Bahn network without disrupting operations underscores the performance of the ESE S. We look forward to continuing to optimize the ESE S and setting new standards in the industry.