Metra Group, headquartered in Rodengo Saiano, Italy, is a global manufacturer of complex extruded aluminum profiles, supporting the needs of industrial, building and construction, and other markets. A key strategic sector for the company for decades has been the railroad industry, which is seeing growing demand for aluminum as the industry focuses on improving the sustainability of its trains and operations. In response to this increasing demand, Metra formed a new business, Metra Rail, in order to better support the development of advanced rail components comprised of sustainable aluminum.
“Metra plays an important role in the advancement of sustainable rail transportation,” said Francesco Bongiovanni (Figure 1), director of Metra Rail. “By providing aluminum solutions that reduce vehicle weight, we help to decrease energy consumption and CO2 emissions, therefore supporting the overall transition to a sustainable economic system.”
Company Profile
Metra was originally founded under the name IMET in 1962 as a producer of extruded profiles. In the decades following, the company grew its operations through expansions and acquisitions to become a global, vertically integrated manufacturer of complex extruded aluminum profiles. The company has ten production plants located in Italy, Canada, and the U.S., which are capable of providing extrusion production, as well as high value-added services (including painting, anodizing, machining, welding, and assembly). The company has an estimated overall capacity of 190,000 tpy and serves a wide range of industries, including automotive, building and construction, industrial, and the rail sector.
Over the past five years, Metra has experienced significant changes and growth. Notably, Metra Group was acquired by KPS Capital Partners, a private equity fund based in New York, in July 2021. Transitioning ownership under KPS enabled the company to merge its European presence with companies like Profile Custom Extrusions, LLC in Rome, GA (which was also acquired by KPS in July 2021)—bolstering Metra’s market presence in the North American market.
In addition, Metra has implemented strategic acquisitions to expand its capabilities and global presence. In September 2021, the company purchased Rustici S.p.A., a manufacturer of aluminum structural components for the rail industry (discussed later). In October 2023, they acquired Belding Machinery and Equipment Leasing, LLC and its subsidiaries, including Extruded Aluminum Corporation (EAC), supporting their further expansion into the North American market. These developments enable Metra to further diversify their end markets into transportation, military, solar, and rail.
Supporting the Rail Industry
Lightweighting is an important element of rail design, ensuring that train car bodies are able to achieve axle load requirements for hauling cargo or transporting passengers, increase train speeds, reduce fuel consumption, and improve the stability of the train during operation. Aluminum has emerged as a crucial material of choice in this regard due to its light weight, high strength-to-weight ratio, corrosion resistance, versatility, and recyclability. As a result, aluminum railcars have been used in suburban metro systems, high-speed intercity, and long-haul trains in Europe, China, and Japan. While the upfront costs are marginally higher for aluminum railcars, the savings over time are significant, particularly in regard to rail infrastructure and carbon emissions. In addition, the use of aluminum in rail cars reduces aerodynamic resistance and transmission loss, significantly improving energy efficiency. Lightweighting with aluminum also results in lower wear and tear to rails and rolling stock.
Aluminum extrusions—particularly structural extrusions with large dimensions—are crucial for constructing these lightweight train bodies, with the material being used in side walls, roof panels, floor panels, and end walls. Alloys in the 6000 series (e.g. 6005A, and 6082) are the most common types implemented, since they are known for their excellent strength.
“The rail industry is undergoing a period of modernization and expansion, driven by factors like increased demand for sustainable transportation, infrastructure development, and the need for high-speed rail networks,” said Bongiovanni. “This poses some interesting opportunities and challenges. The opportunities come with the growth of sustainable transportation goals and decarbonization trends, which is expanding the market leveraging on the global trend of economies of proximities in urban areas. The challenges come from the global supply chain, which has experienced some fundamental shocks in recent years, such as COVID, rising energy costs, and now the tariff economy. The rail market will have to address these challenges in order to exploit the potential growth.”
Metra has been a part of the rail industry supply chain since 2001. A significant milestone in their development of this market was the installation of high-capacity, 7,000 ton presses, which allow them to manufacture large, complex aluminum profiles up to 30 m long and 700 mm wide for structural components in modern rail cars. Over the years, the company has continued to evolve as a specialized supplier for the rail industry, expanding its capabilities to include advanced welding, machining, and finishing. This allows them to supply ready-to-assemble sub-components, streamlining the production process for rail OEMs. Metra is certified to the International Railway Industry Standard (IRIS) ISO 22163:2023 (renewed in September 2024), which is specifically designed for companies operating in the rail sector and covers the company’s foundry, extrusion, machining, and welding operations, as well as EN 15085 for the welding of railway vehicles and components.
“Metra’s growth is mainly in Europe, where it supports rail OEMs in the transition to aluminum trains where the trend is driven by economies of proximity to urban areas,” said Bongiovanni. According to the company, its presence in the rail sector has grown from a turnover of €10 million with around 2,000 tons of profiles sold a few years ago to an estimated €85 million with about 7,000 tons sold in 2024. The company has been involved in more than 37 rail projects, with its products being installed on platforms ranging from mass-transit to high-speed rail cars.
In order to strategically support this business, the company launched the Metra Rail brand, with Francesco Bongiovanni as its director. Bringing its rail business under one brand enables the company to better solidify its position in the sector, allowing it to integrate its manufacturing and value-added activities and optimize its operations through continuous investment.
Acquisition of Rustici
Founded in 1969 and headquartered in Pistoia, Tuscany, Italy, Rustici S.p.A. is a manufacturer of aluminum structural components, primarily for the railroad industry. The company operates two manufacturing facilities, from which it provides welding, machining, and assembly of extruded aluminum profiles. It is a long-standing partner of large OEMs in the rail industry, supplying welded structural sub-assemblies.
Metra completed the acquisition of 100% of Rustici in September 2021 as part of its strategy to expand its services and strengthen its position in the rail sector. Merging the two companies provides Metra with additional welding and assembly expertise. This allows the company to diversify its proposals to existing and potential customers, enabling them to offer a broader range of products and services, as well as additional expertise in aluminum extrusion. In turn, Rustici gains access to Metra’s global network, allowing it to reach more customers in Europe and North America.
“Rustici is considered to be one of the best companies in our country specialized in aluminum welding and structural assembly and has a strong reputation in the rail industry for quality and technical expertise,” said Enrico Zampedri, CEO of Metra, after completing the acquisition. “Its capabilities and services are complementary to Metra and will provide additional growth opportunities in this key sector for the company’s future.”
Rail Manufacturing Capabilities
Metra has two plants dedicated to the rail sector, located in Italy, including its headquarters in Rodengo Saiano for extrusion and fabrication and the Montale plant for fabrication. Investments in its Rodengo Saiano facility expanded the company’s machining, welding, and quality controls, including the introduction of welding portals, robots, and most recently friction stir welding (FSW). Furthermore, the introduction of laser cleaner technology increased the standards in the weld seams cleaning process. The company’s welding capabilities were further expanded through the acquisition of Rustici S.p.A.
Fabrication, welding, and finishing are necessary for the production of structural extrusions according to the strict tolerances required by the rail sector. Metra’s advanced CNC machining capabilities allow for the large-scale machining of profiles up to 30 m long (Figure 2). Advanced welding enables the assembly of large and complex rail structures, which is essential for creating robust and reliable rail components (Figures 3-4). Metra also provides painting and anodizing services, which enhance the corrosion resistance and aesthetic appeal of rail components. This ensures the longevity and performance of the parts, which are exposed to harsh environmental conditions, such as thresholds and baggage compartment parts. In addition, the company’s logistics system provides efficient material handling with timely delivery, which is critical for meeting the demanding production schedules of the rail industry.
“Metra is continuing to invest in processes, technologies, and knowledge,” said Bongiovanni. “A key example is the partnerships created with main universities in Italy and with specialized suppliers. The focus on internal capability is the core, with large investments going on in all extrusion, machining, and welding applications.” He also noted that Metra has established a welding school to grow young talent in the manual welding to fuel future growth in all welding solutions.
Conclusion
Metra has been strategically advancing its position in the rail industry for over two decades. With the formation of Metra Rail, the company is able to concentrate its aluminum extrusion, fabrication, welding, and assembly activities to better serve new and existing rail customers. “Metra’s goal is to establish ourself as a global partner for all services and solutions related to the rail industry,” said Bongiovanni. “With our team of professionals and state-of-the-art capabilities, we will further expand into key products and markets, along with our ongoing investments.”
Editor’s Note: This article first appeared in the June 2025 issue of Light Metal Age. To receive the current issue, please subscribe.