The gates at Optare’s factory in Blackburn have closed to allow final clearance of the site, bringing 80 years of bus manufacturing in the town to an end. However, the move marks the start of a new era for the company, now reborn, re-energised and secure as part of global busmaker Ashok Leyland.
Formerly the home of East Lancashire Coachbuilders, which traces its history back to 1934, East Lancs expanded in to the current location on Lower Philips Road in 1994 and was soon building both single- and double-deck bodies, establishing itself as a supplier of high-quality buses to large and small operators throughout the UK.
Over the years East Lancs has built trolleybuses, trams, a small number of narrow gauge railway carriages, and also had a high degree of export success with double-deck and open top deliveries to Paris, Madrid, Barcelona, Copenhagen and Luxembourg.
The East Lancs business became part of the British Bus Group in the late 1980’s supplying not only to the parent group, but also to a large number of municipal operators and the growing number of independents.
On the sale of British Bus Group to Cowies, which later became Arriva Passenger Services, East Lancs once again had to reinvent itself and began to focus on the increasing number of independent operators in the tendered services of Transport for London. As a result, large numbers of double-deck vehicles were sold to Capital Citybus, Harris Bus and Metrobus. However, due to market difficulties and several other factors, the company went into administration in August 2007 but was saved by the Darwen Group a day after the announcement.
In 2008 Jamesstan Investments, an investment company controlled by the Darwen Group purchased Optare and later the same year, a reverse takeover was performed, with the Darwen name being dropped in favour of the much stronger Optare brand.
As part of a 3 year turnaround plan, restructuring of the Optare business started in August 2009 with closure of the Rotherham site followed by relocation of the Leeds factory in November 2011 and now finally the Blackburn closure in May 2012. With all of its bus assembly operations now consolidated into a state of the art facility in Sherburn in Elmet, Yorkshire, the benefits are already showing with production volumes ramping up, demonstrated by the latest UK bus registrations published by the SMMT, showing an increase of just over 50% year to date.
Jim Sumner, Optare CEO said “The task of progressively closing three factories and relocating to a single site has been an extremely challenging process. There were always going to be unpleasant elements which I don’t take lightly, and I sincerely wish former employees all the very best for the future. Could I also acknowledge the support and patience of our customers and suppliers during this difficult transition period. Clearly, in an extremely competitive market, the survival of the business has had to be my prime concern and this process has been a key element in turning the business around.
“Having everything on one site is undoubtedly the most efficient way for any business to operate and we have significantly reduced our overheads and operating costs as a result of this strategy. Under the new ownership of Ashok Leyland, we are now poised to realise the full benefit of this strategy along with the significant product investments made over the past 3 years”
Picture caption: Optare Sales Director, John Horn closes the Blackburn factory gates for the last time.
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Two electrically powered Optare Solo SRs are now being trialled on a route between Dorchester and the ‘model village’ of Poundbury. The vehicles, funded by the Duchy of Cornwall, West Dorset District Council and Dorset County Council, are expected to embark on passenger carrying service duties in a few weeks time. This is the first time the SR model has been powered by electricity.
Poundbury has been designed by the Duchy of Cornwall, with close personal involvement from HRH The Prince of Wales, and is an eco-friendly urban extension to the County Town of Dorchester. Poundbury is famous internationally as a pioneering example of “New Urbanism” and has been established on principles set out by The Prince of Wales in his 1989 book ‘Vision of Britain’.
The vehicles feature the Enova P120, zero emission, full electric drive system which has been selected for its optimised application in smaller vehicles. The motor power is 120kW with a torque rating of 650Nm and there are 56 maintenance free, lithium iron magnesium phosphate batteries housed in two separate packs which are assembled in parallel. The 100kWh battery pack is expected to give an operating range of around 90 miles on a single charge.
Charging is via a water cooled 15.2 kW on-board charger which achieves full capacity in around 6 hours. The charging process is fully automated and the unit shuts all systems down at the end of the cycle enabling the vehicle to be left unattended.
The Solo SR’s are 8.9 metres in length and are fitted with 28 leather trimmed, Esteban Civic V3 seats, incorporating integral headrests. Mobitec LED destination and route number equipment is fitted together with an ACIS passenger information system.
Further information will be given about the vehicles and this innovative service at the time of an official public launch planned for early July.
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A further ten Optare Versas are on their way to Transdev Blazefield. Eight are for Harrogate using the new Harrogate Connect brand and two for Burnley using the popular Starship brand.
The exterior livery of the Harrogate Connect vehicles is an eye catching combination of black and burgundy, while the Burnley vehicles retain their familiar Starship orange and yellow paint scheme.
Each vehicle is powered by the Mercedes-Benz OM904LA Euro 5 SCR engine rated at 115kW which drives through the Allison 2100 series five speed fully automatic transmission; a well proven combination, perfectly balanced to return exceptional performance and fuel efficiency. The Optare standard Ecodrive instrument panel which provides the driver with direct feedback as to how their driving style is influencing fuel consumption is an added aid to reducing environmental impact.
All round disc brakes combined with a KLAM electromagnetic retarder and ABS assure optimum efficiency and safety in operation, while the full air suspension gives excellent ride and handling characteristics.
As with the previous 25 vehicles which were delivered in 2007 and 2008, the 11 metre version is once again the preference, and each is fitted with 36 seats; 30 moquette trimmed Esteban Civic V3 seats with integrated headrests, and six tip-up seats in the wheelchair/buggy bays.
A Compak powered ramp is installed in the entrance step platform enabling deployment by the driver without the need to leave their seat should wheelchair occupants, or mums with buggies need to board or alight, and front end kneeling ensures an easy step height or ramp angle is achieved.
Mobitec LED electronic destination and route number displays are fitted to the front, side and rear giving passengers waiting at the bus stop, a clear and unmistakable indication of the operating route as the vehicle approaches, and a multi-camera CCTV system is installed for security and passenger safety.
Chris Wise, Optare Commercial Director said “It is pleasing to see more Versas being delivered to Transdev Blazefield. I think the modern body styling coupled with the eye catching exterior paint schemes works exceptionally well. We have worked closely with Blazefield to ensure that both inside and out, these vehicles are designed for maximum passenger appeal, and I’m sure this will serve to increase ridership”.
Nigel Eggleton, Transdev Blazefield Marketing Director agreed adding “We need these new buses to turn heads. A combination of excellent design from Optare combined with the ‘wow’ factor of the new colours will ensure recent growth in the Harrogate and Burnley markets continues and accelerates.
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A total of 39 Versa hybrid vehicles designed specifically for use as school buses, and which are thought to be the first hybrids dedicated solely to this type of operation, are set to enter service after the Easter holiday.
They are also believed to be the first buses built specifically for this application that fully meet R66 roll-over regulations.
Produced at Optare’s new plant at Sherburn in Elmet in Yorkshire, the Versa hybrids represent an investment by Transport for Greater Manchester (TfGM) of around £9 million under its ‘Yellow School Bus’ scheme and are part-funded through the Government’s Green Bus Initiative.
Optare’s modular construction was a key factor in the design which is based on a specially adapted version of the Versa model. This has resulted in a total passenger capacity of 57, achieved by using a 3 + 2 seating configuration, with all passengers on Rescroft CT Lite seats fitted with full 3-point safety belts.
Power is provided by a Mercedes-Benz OM904LA 130kW, Euro 5 diesel engine. This drives a generator and resultant energy is stored in roof mounted super capacitors.
There is no physical connection between the engine and the rear axle. Propulsion is provided through twin electric motors and a summation gearbox connected to the axle. During deceleration the drive motors regenerate brake energy which is used to top-up the super capacitors. When the vehicle pulls away, stored energy is used to accelerate, and engine rpm does not need to increase.
This combination is expected to achieve fuel savings of up to one third when compared to a conventional diesel driveline. Other significant environmental benefits include lower carbon dioxide emissions, reduced noise levels and a smoother ride.
The Versas will be operated by several bus companies in the Greater Manchester area under contract to TfGM and in compliance with its ‘Yellow School Bus’ requirements. This includes using regular drivers who have been specially trained, strict rules on behaviour by users of the service, and the fitting of a comprehensive CCTV system on each vehicle.
These vehicles represent the final deliveries of a total of 88 hybrid buses ordered by TfGM under contracts through the Green Bus Fund 1 & 2 initiatives.
John Horn, Sales Director at Optare, added: “We are very pleased with the outcome of our close collaboration with TfGM, which has resulted in these high quality school buses, built at a very competitive price, and which are cost effective to operate.
“The young people travelling in these vehicles will be doing so in considerable comfort and safety while the use of hybrid technology is contributing to a cleaner and quieter environment in their local communities.”
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The latest fleet of Optare Tempo buses has entered service with Traws Cymru on the new T4 route linking Newtown, Llandrindod Wells, Builth Wells, Brecon, Merthyr Tydfil, Pontypridd and Cardiff.
The new fleet of vehicles, which have been carefully designed following consultation with passengers, are part of the £2.2m Welsh Government investment to improve and expand the former Traws Cambria bus network.
Speaking at the recent launch ceremony, Carl Sargeant the Minister with responsibility for Transport said: “Developing and encouraging the use of sustainable transport is key to improving connectivity across Wales.
“This new service between Newtown and Cardiff is the result of the Welsh Government listening to what people want, and delivering a green service that meets the needs of local communities by providing a key public transport link between major centres.”
The T4 route, operating once every two hours in each direction, Monday to Saturday, is the first to be introduced as part of a network of new Traws Cymru longer distance coach style services in the region.
The revamped service has been developed following consultation with passengers who requested a faster and direct service between key communities in eastern Powys and Cardiff and is funded by the Welsh Government as part of its commitment in the National Transport Plan for Wales to promote high quality, environmentally friendly public transport services across Wales.
With a round trip of almost 200 miles, passengers travelling along the route can expect a high level of comfort and luxury. The vehicles are double glazed with full climate control, and high backed, leather trimmed executive coach type seats are fitted throughout, together with parcel racks and a two-tier heavy-duty luggage pen.
There are two tables to the rear of the vehicle with fore and aft facing seats. Beneath each table is a twin, 240 volt power point for lap-top computer/mobile phone charging, and full Wi-Fi is provided throughout the vehicle so passengers can surf while they ride.
A GPRS controlled real-time passenger information system is fitted for convenient journey planning, together with an induction loop system to help the hearing impaired communicate more effectively with the driver. These features, coupled with a multi-speaker radio/CD player, and a driver’s hands free public address microphone, complete the comprehensive audio visual package.
Security, and passenger safety is assured via the 8 camera CCTV surveillance system which has a high definition hard drive recording facility.
Six, 12 metre Optare Tempo vehicles are dedicated to the T4 Service, and have high profile exterior branding to advertise the fact.
Powered by the 210kW Mercedes-Benz OM906LA, six cylinder turbo-charged engine, and driving through the Allison T310R fully automatic transmission, which has an integral retarder and a lock-up torque converter, the heavy-duty, low-weight integral construction used in the manufacturing process results in an exceptionally low unladen weight delivering reliability and class leading fuel efficiency.
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At this month’s Delhi Auto Expo, Optare showcased its Ashok Leyland branded Solo – the first low floor midibus to be offered in the Indian market.
The vehicle on show has an interior developed to suit Indian operating conditions. It also features a 110 kW ‘H’ Series engine (BS4) of proven pedigree from Ashok Leyland, ensuring a high degree of fuel efficiency. The on-board diagnostics, familiar to UK Solo operators, offer useful information to both the driver and owner to enhance operating economics.
Solo of course features all welded fully integral body construction in low-weight stainless steel, a first in India, and makes it one of the safest vehicles on Indian roads, it is claimed.
Tailored to a variety of applications – from shuttle services to tourist operations – the Solo enables Indian customers to opt for various lengths (from 7.1m to 10m) and differing seating configurations to offer either more standees (tarmac applications) or more seats (staff buses).
“ It’s with some pride that we at Optare saw the Solo make its Indian debut. Although of course our core model has enjoyed export success before, that has always been in the so called ‘sophisticated’ markets of Europe and North America. Developing a model to operate in the testing traffic congestion and climatic conditions of India is a real accolade for our joint design and engineering teams in Leeds and Chennai”, said Charles Waggott, Optare’s Export Director.
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A meeting of Optare plc’s shareholders at the company’s state of the art bus assembly plant in Sherburn in Elmet today has given overwhelming support to a plan which secures the company’s long term future with Ashok Leyland.
More than 99.9% of the shareholders who voted backed the deal under which Ashok Leyland will increase its stake to 75.1% of Optare and simultaneously fully integrate Optare and its advanced product range into Ashok’s Global Bus Strategy. Turnout was over 70%.
“ This is a real vote of confidence in both Optare and Ashok”, said Jim Sumner, Optare’s CEO. “Even though the plan has involved diluting current shareholders, it is recognised that this deal is in the best interests of the business long term and secures its future within one of the world’s top five bus makers”.
“ It will also have tangible benefits for Optare’s employees, customers and suppliers who will benefit from the growth we predict in the coming years in both UK and export markets”, said Mr Sumner.
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Optare has announced the end of production of its original Solo design after some 14 years. The original model is being retired in favour of the new look Solo SR for both UK and exports markets.
Since its introduction in 1997, more than 4,000 of the original Solo design have entered service in the UK, including exports to the USA, Western Europe and beyond.
The first vehicles which were delivered to Wilts and Dorset, now part of Go-Ahead group, continue to operate in daily passenger-carrying service and in total, Optare Solos in the UK alone are estimated to have clocked up over a billion miles.
The Solo SR was launched in 2007 as a premium model with an entirely new exterior appearance and has grown significantly in popularity. The new 2012 Solo SR range will consist of 7.1m, 7.8m, 8.9m and 9.6m variants, all available in the Slimline (2350mm wide) version. The 8.9m and 9.6m models will also be available in the wider 2500mm body width. All will feature curved side glazing and high specification interiors allowing up to 37 seats in the longest derivative.
The opportunity has been taken to redesign some of the bodywork components to take advantage of the benefits achieved on the recently released Tempo SR design which reduce both weight and cost and further improve fuel economy.
Glenn Saint, Optare’s Chief Operating Officer, said: “Moving to the single body exterior and interior design will give all operators the benefit of the enhanced features of the Solo SR but the increased volume this creates will allow pricing to remain competitive with other products on the market”.
Building upon the existing mechanical design ensures continuing proven reliability and with no surprises from untested new designs. All Solo SR models will be available with either Mercedes-Benz or Cummins drivelines allied to Allison transmissions.
The move to the standardised Solo SR range will take place during the summer of 2012 following delivery of current order commitments.
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Further to the announcement on 25th November, UK bus manufacturer Optare plc can now confirm it has signed a contract worth up to £18 million under which it will supply 190 of its Solo SR midibus model to the City of Cape Town. The fleet of buses will form a key element of a Bus Rapid Transit (BRT) network being introduced by the City Council as part of a world-class Integrated Rapid Transit (IRT) system combining all modes of public transport.
Optare won the business through a comprehensive competitive tendering process involving a number of global bus makers. Central to Optare’s success was the support provided by Ashok Leyland and the partnership forged with South Africa’s leading bus assembler Busmark 2000, who will produce the buses at a new plant in Cape Town from kits of components and sub assemblies supplied by Optare.
Optare Chief Executive, Jim Sumner, said: “I am delighted that our focussed efforts on growing our overseas business continue to yield results, in this case with the award of a very significant contract from one of the world’s most exciting cities. We knew from the start that we had the right product in our stylish and fuel efficient Solo SR model.
“We look forward to building on this contract to supply further vehicles into this important market, and to show that with our new state-of-the-art facilities at Sherburn in Elmet, Yorkshire, and the significant support of our strategic partner Ashok Leyland, we can meet demand for fleet volumes of buses at an internationally competitive cost both at home and abroad.”
Under the contract Optare is supplying the 8.9 metre version of its Solo SR model powered by the Cummins ISBe six-cylinder engine. This meets Euro 5 emissions standards in line with the environmental requirements of Cape Town Council’s IRT strategy. The 201 horsepower (150 kW) engine will be matched to an Allison five-speed automatic transmission incorporating a lock-up torque converter to support better fuel efficiency.
Cape Town’s IRT Authority will operate the buses in conjunction with the local minibus-taxi associations, who currently provide a large part of the public transport services in the city. Operating under the MyCiTi brand, they will replace the minibuses and provide faster and more efficient feeder services from outlying townships to rail terminals using dedicated bus lanes on main routes. Cape Town City Council will take delivery of the first 60 vehicles by June of next year with the balance to follow before the year end.
Unusually the vehicles will have both a conventional forward access door on the nearside and an exit door on the offside. This will facilitate fast discharge of passengers at the railway terminals from where they will complete their journey into the city centre by train.
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The long term future of British bus maker Optare plc has been secured thanks to a refinancing agreement announced today. The deal involves Ashok Leyland increasing its holding in Optare to 75.1% allowing Optare to become fully integrated in Ashok’s ambitious global bus strategy which seeks to maintain and improve on its top five place amongst the world’s bus makers. Ashok Leyland Ltd is the flagship company in India of the Hinduja Group.
The refinancing is being achieved by Ashok Leyland providing a guarantee to support Optare’s re-banking which will provide a substantially improved working capital facility for the business. At the same time, Ashok Leyland will increase its stake to 75.1 per cent of the Company’s share capital through a placing of shares raising new equity.
Ashok Leyland’s global bus strategy encompasses the role of Optare in enhancing Ashok Leyland’s product portfolio and global footprint. The existing contractual and statutory employment rights and pension rights of all Optare employees will be safeguarded.
CEO Jim Sumner said: “This is great news for Optare’s customers, employees and suppliers by securing stability and the long-term future of the business. The re-banking of Optare represents a critical milestone in the turnaround of the business and allows us to now complete the final phase of the three year plan which commenced in June 2009”.
“In addition, our recent move to a new factory in Sherburn gives us the capacity and modern assembly facilities necessary to capitalise on the additional sales our deeper partnership with Ashok Leyland will undoubtedly deliver”, he also said.
John Fickling, Chairman said: “Given the global economic challenges we all face, this is a game changing deal for Optare. It ensures that we can grow and prosper in an ever changing and demanding market place”.
Vinod Dasari, Managing Director, Ashok Leyland observed: “We see this as an important element in realizing our vision of being among the top five bus manufacturers globally. Through leveraging the synergies of the two companies, we are confident that going forward we will be able to accelerate technology sharing, develop future-ready products and increase our global footprint to fast-track our growth in volumes”.
Dheeraj Hinduja, Chairman of Ashok Leyland said, “We are confident that, together with Optare, we can surge ahead leveraging historic British manufacturing excellence and taking advantage of the large opportunities for growth and development we see based on synergy and integration with the Ashok Leyland bus business”.
About the Hinduja Group:
Hinduja Group is an investment and banking group with a diversified global portfolio of holdings across the manufacturing services and banking sectors. The Group, founded by Shri P.D. Hinduja in 1914 has activities across three core areas: Investment Banking, International Trading and Global Investments. It also supports charitable and philanthropic activities across the world through the Hinduja Foundation. As part of its Global investments, the Group owns businesses in Automotive, Information Technology, Media, Entertainment & Communications, Banking & Finance, Infrastructure Project Development, Chemicals & Agri business, Energy, Real Estate, Trading and Healthcare. www.hindujagroup.com.
About Ashok Leyland:
Ashok Leyland is the flagship of the Hinduja Group and a leading Indian commercial vehicle manufacturing company based in Chennai selling approximately 94,000 vehicles and about 17,000 engines annually and is the second largest commercial vehicle company in India in the medium and heavy commercial vehicle segment, with a market share of about 25.7 per cent. in 2010 -11. Ashok is a market leader in the Indian bus market selling over 23,000 buses annually. The sales turnover of Ashok in 2010-11 was US $ 2.5 billion. Ashok has seven plants in India, one in the Czech Republic and one in the Middle East with a current global capacity of over 150,000 buses and trucks. In 2006 Ashok became the first automobile company in India to achieve the internationally renowned TS16949 certification.
About Optare:
Optare is Britain’s leading maker of advanced low-floor integral buses and employs around 500 people across the group, principally at its new assembly facility in Sherburn in Elmet, Yorkshire. The company produces a wide range of fuel efficient buses of its own integral design. In addition Optare has pioneered its ‘EcoDrive’ programme across all of its products which deliver a wide range of low carbon power options, including hybrid, full electric and dual fuel models.
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