MATC Fall Lecture Series: Dan Sabin
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University of Nebraska October 19, 2012
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Railroad Operating and Engineering Managers--Seeing the
Big Picture
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Iowa Northern Railway Company
Formed from liquidated Rock Island main line, on February 22, 1984
Purchased from on-line elevators and Iowa-Electric Power in November, 1994
IANR covers North Eastern Iowa with 195 route miles
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The early years—The Railroadused as a cattle pasture—
No Traffic on the Line
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Iowa Northern Railway
IANR is a unique short line with multiple rail connections providing independent access to North American Rail System.
Aggressive in economic growth and development in market area.
Averaged 18% annual growth between 2003 and 2011, despite recession and two years of major flood recovery.
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IANR has multiple railroad connections with BNSF, CN, CP, IAIS (through CIC)
and UP
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Iowa Northern Philosophy Run the Company like a business, not like a railroad. Encourage customers to grow their business with great service
and fair, competitive freight rates. Create new business. Be the solution. Tap the strengths of
each rail connection. Empower employees
to do their best in safe and creative ways.
Support the State andCommunities served.
Take some risk. Facilitate new
industries and growth. Be easy to do
business with. Repeat, don’t act like a
railroad.
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The Company’s Markets Grain Ethanol Wind Components Machinery Chemicals Fertilizer Bulk Products Food Products Bio-Mass Distillers Grains Corn Oil Trans-load
Commodities9
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Originally just a grain hauler, IANR elevators have increased volumes of grain from 230 cars per month
in 1994 to nearly 2,000 per month today.
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Grain Traffic In a normal crop year, nearly 1 billion bushels of corn is grown
along the IANR. IANR will handle nearly 22,000 carloads of corn, soybeans and
oats in calendar year 2012 compared to 10,500 carloads in 2001. Most of the traffic moves to Cedar Rapids, providing high utilization of hopper cars.
If Cedar Rapids was an independent nation, it would rank third in the world in the importation of corn, behind only Japan and Mexico.
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Drought Effect on IANR IANR will miss about 6,000 carloads of
corn in 2012 that would have moved in a normal crop year. This will reduce IANR revenues by about $4 million.
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Ethanol Related Products
Iowa Northern has grown from zero car loads of ethanol related products in 2005 to 14,000 annual car loads in 2011.
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Creation of New Business
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Three large fertilizer terminals have been established along the line with more
expansion planned.
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Iowa Northern Wind Energy Business
IANR wind component distribution center at Manly is the largest in North America.
Future wind business is contingent on extension of tax credits for wind energy.
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IANR handles Wind, Ethanol, Corn Oil, feed
additives and Chemicals at Manly Terminal
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IANR provides rail to truck transload service at several locations, with new infrastructure at
Waterloo and Manly
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Bryant Yard Trans-loading• Two new reload tracks have been built adjacent to IANR’s Bryant Yard in
Waterloo to provide the ability to grow the business. Additional commodities: powdered clay, tomato paste, magnesium chloride, lube oil, bentonite clay.
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IANR provides container handling service for inbound wind components at Manly
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IANR delivers John Deere Tractors from Waterloo to UP at Cedar Rapids and Manly
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Flood—2008!!
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Flood 2008 Major bridges at Waterloo and Cedar
Rapids destroyed by flooding, cutting IANR into two separate segments.
Lost traffic and additional costs of $800K per month. Included 150-300 mile detours.
Line was segmented for 18 months. Long term flood mitigation efforts will
continue for decades.
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What’s new at IANR?
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Acquisition of Non-Powered Slugs to reduce emissions and fuel burn
A slug is a vehicle used for moving trains, having traction motors and added weight (or "ballast") but no prime mover or generator. The electric current for its motors is provided by a
"mother" unit, a standard locomotive fitted with cable connections to feed current to the slug. A locomotive
produces more power than it can use at low speeds. A slug can pull as much as the mother, but does not burn any fuel
and discharges no emissions.
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Forest City-Belmond LineSaved the 28 mile line from abandonment-
November 2011
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IANR is pleased with initial traffic volumes of the 30 mile Garner Subdivision Acquisition
Purchased the line from UP and started operations in November, 2011 as a joint venture with the community. Absorbed into base operations.
IANR expected losses for the first year of operations—modestly profitable from the start.
More traffic handled in first month than the line handled in the past five years.
Averaging nearly 100 loads per month in first ten months of operation—corn and fertilizer.
The line is well suited for industrial growth. A gateway for a new market territory for IANR.
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Bio-Mass Material Regulators will require at least 10-20% biomass fuel for coal
burning power plants and a whole new industry is developing to convert crop waste into all types of fuels.
Iowa Northern has approximately 12 million tons of excess crop waste within 30 miles of the line, equivalent of 75,000+ carloads annually.
Biomass will provide exceptional new revenue base to farmers. Biomass products could be the next major commodity handled
by railroads.
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Future Plans
Butler Logistics Park
Manly Logistics Park
Garner-Forest City Logistics Park
Palo Logistics Park
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Butler Logistics Park Terminal A major Industrial development expected to exceed 300 acres
. Site of future rail yard and locomotive shop. Two new industries breaking ground in Q4 2012
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Manly Logistics Park will be the major logistics campus in the State of Iowa
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Manly Logistics Park
Manly Terminal
UP Spine LineUP connection to Manly Yard
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Manly Logistics Park A major development adding 162 acre park
dedicated to reducing costs to shippers in North Iowa and Southern Minnesota
Trans loading facility for misc. commodities including lumber, machinery, distillers grains, edible beans, stuffing containers
Steel Distribution Center-Steel coils and plates inbound by rail, outbound by truck to Midwestern markets
Cold storage and freezer warehouse of major size with rail cross dock
Substantial intermodal facility for Northern Iowa-Southern Minnesota
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New Steel Distribution CenterGround Breaking in November
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Meat and Eggs-Refrigerated and Other Food Products
Iowa is the largest egg producing state, as well as high volumes of meat and poultry products, processed foods.
Iowa lacks appropriate and efficient access to intermodal, particularly Texas, Mexico and California traffic lanes.
High fuel surcharges are hurting competitive access to Northern Iowa-Southern Minnesota producers.
New facilities are planned to accommodate the massive volumes of dry and refrigerated-frozen food products on Northern Iowa and Southern Minnesota.
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Intermodal Base Case Iowa is a small consumption state, so it has a severe imbalance
of inbound vs. outbound containers. According to US Census Bureau Data, the 2011 ratio of non-bulk international commerce in Iowa is 1:3 inbound to outbound. This creates a severe shortage of empty containers available to Iowa producers for loading. Empty containers must be shipped or “drayed” into Iowa to meet demand.
Minnesota’s international commerce is opposite that of Iowa. The 2011 ratio of non-bulk international commerce in Minnesota is 6:5 inbound to outbound. Taking a regional approach with consolidation of the two states provides an almost even match of 7.2 : 7.6 inbound to outbound.
A new, efficient intermodal terminal in North Central Iowa can draw inbound and outbound container loads from a widespread region including the Northern half of Iowa and Southern Third of Minnesota.
Minnesota lacks direct intermodal service to/from Texas/Mexico and California which can be provided through a north Iowa facility.
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Manly is a strategic location for a new Intermodal Terminal
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Manly Logistics Park layout design with intermodal facility included
Additional transload tracks, a major steel distribution center, refrigerated-freezer cross dock and warehouse operation planned adjacent to intermodal site, allowing consolidation, stuffing of heavy containers.
Major truck base planned near MLP.
Sand Processing
Trans-Load Tracks
Steel Distribution
Cold Storage Warehouse & Cross Dock
Intermodal Facility
Loop Track
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Union Pacific Overhead
Nearly 20,000 Revenue Cars Annually
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CPR Overhead TrafficAbout 6,000 Revenue Cars Annually
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Expected Iowa Northern Railway Growth from 20,000 to 105,000+ carloads in 15 years-
IANR Climbing to Class II carrier in 2012
0
10000
20000
30000
40000
50000
60000
70000
80000
90000
100000
1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
Carloads
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Comparing Pre-Flood with Post Flood Financial Performance
0
5000000
10000000
15000000
20000000
25000000
30000000
35000000
Revenues
Opr Expenses
EBITDA
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Operating Managers Have Direct Connection to Bottom Line
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Financial Performance
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
35,000,000
Revenue
Cash Expenses
Net Cost Capital Spending
EBITDA
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Train Crew ProductivityUp is Good
0
5
10
15
20
25
Revenue Cars Per Crew Start
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Correlation of Crew Starts to Revenue Cars Handled
0
500
1000
1500
2000
2500
3000
3500
4000
0
10000
20000
30000
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60000
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Rev Cars
Crew Starts
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Revenue Per Crew StartUp is Good!
01,0002,0003,0004,0005,0006,0007,0008,0009,000
10,000
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
Floo
d 20
08
Floo
d 20
09
2010
2011
2012
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Fuel Burn Per Revenue CarDown is Good
0
5
10
15
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25
30
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
Floo
d 20
08
Floo
d 20
09
2010
2011
Proj
201
2
Gallons Per Revenue Car
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Fuel Burn Per Crew Start
0
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300
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1995
1996
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2002
2003
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Floo
d 20
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Floo
d 20
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2010
2011
Proj
201
2
Fuel Burn Per Crew Start
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Enforce Fuel Efficiencies
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Reduction in Fuel Burn—Engineer Training & Enforcement
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Best Use of Slugs
Slugs placed in service on the North End with 24/7 operations, slow orders and work at every station.
Expanding slug fleet from 2 to 6 units. Payback in 10 months in fuel savings.
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Capital Spending
Iowa Northern continues to upgrade its line and provide more capacity for growth. Will have
spent over $100 million along the line by 2015.
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Manly Yard Critical to operations
and industrial development.
Relocated elevator tracks to eliminate route conflict.
Tracks 7-12 in place. Tracks 2-6 under
construction. Lights added for night
crew safety and security.
New car repair facility is open.
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Continued upgrading of the Railroad
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Increased Yard and Side Track Capacity-100K Main Line wood ties, 75,000 Steel Ties and 42 miles of new Continuous Welded Rail (CWR)
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Eliminate Slow OrdersDown from 46% to 32% slow ordered
main line track in 18 months
0
10
20
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50
60
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Cedar Rapids Sub Manly Sub
Total Miles
Slow Orders 12/10
Slow Orders 9/12
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Continuous Welded Rail (CWR) ROI
Total investment 2008-2012 42.67 miles cwr $12.75 million.
Derailment Cost Avoidance Since 2001, Annual Derailment Costs / Mile
CWR Caused Derailments - $0 / mile Non-CWR Caused Derailments - $ 1,921 / mile With 42.6 miles of CWR this equates to an estimated
annual cost avoidance of $81,834. Fuel Savings & Speed Improvement
Based on GPS and fuel data before and after installation of 16.5 miles of CWR in 2011 & 2012 67% increase in average speed (From 10.39 – 17.34 mph) Saved 4.21 gal / mile (From 10.16 – 5.95 gal) At current diesel price of $3.34 / gal this equates to an
estimated annual fuel cost savings of $437,244 for the entire 42.6 miles of CWR IANR operate two trains per day.
Other benefits to quantify-crew starts, increased track capacity, locomotive utilization and costs, rolling stock utilization and costs.
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Continual increased capacity
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Major Projects handled in-house
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IANR Capital Spending for Increased Capacity
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Increased Operating Capacity
IANR employees are pretty good at building new track.
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Derailment and Other Incident Costs
Year Incidents Cost
Average cost/inc
Total Cars
Handled
Train Miles
Operated
Cost Pct of
Revenue
2000 18 461,124 25,618 23,766 79,970 8.42%
2001 26 566,424 21,786 24,758 81,587 9.63%
2002 28 411,413 14,693 25,531 85,823 6.41%
2003 16 39,447 2,465 26,174 91,418 0.62%
2004 27 56,906 2,108 28,931 91,218 0.79%
2005 21 30,383 1,447 31,608 95,103 0.35%
2006 29 482,541 16,639 39,240 105,449 4.15%
2007 47 861,907 18,338 43,926 133,913 5.47%
2008 53 177,967 3,358 45,416 144,546 0.99%
2009 51 313,095 6,139 43,913 143,692 1.87%
2010 55 877,160 15,948 57,831 184,385 8.14%
2011 45 209,970 4,666 59,074 194,440 0.79%
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Expanded Shop Capacity
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Good Locomotive FleetIANR has 26 locomotives on line to absorb short term growth. Use of Class I power will increase with run-through trains.
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Expanded capacity with additional mother-slugs
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Continued rehab of older units
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IANR Leadership•IANR provides momentum and direction in logistical solutions that cannot be matched by larger, cumbersome organizations.•IANR can work closely with connecting lines, existing and new customers to be responsive to the customer’s needs on a real time basis.•All Departments are responsible for IANR’s success.•Field authority for service needs.
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Iowa Northern constantly redefines targets to create new markets and maintain constant growth.
Iowa Northern must always be more diligent, more responsive, more resilient and quicker to identify new opportunities.
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Hawkeye Express, LLC handles 5,000+ football fans to Kinnick Stadium on each game day. Over 30,000 fans used the train during the 2011
season. We look forward to the Cornhuskers visit on November 23.
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