Sunkid Heege engineers the future of coaster replacement trains

Sunkid is a leading provider of attractions for the whole family, from single attractions to complete turn-key leisure facilities and personal conveyors for outdoor use, all developed by specialist companies within the group.

Among its subsidiaries is Sunkid Heege GmbH, a manufacturer of components, spare parts, and component groups for the leisure industry with a particular focus on vehicles, including complete trains for roller coasters or similar rides.

Michael Kalsch, CEO of Sunkid Heege, last spoke to blooloop in 2023, when he described the company’s product line as having been “delighting children and families around the world for more than 40 years.”

“The hallmarks of our products are their ease of use, small footprint, high level of interactivity, and great fun,” he said.

“They are quality Made in Germany and offer the highest reliability and safety. Our customers all over the world have appreciated this for decades.”

Now, the company has developed a landmark new train that builds on these principles and offers clients a 20% lighter vehicle. This represents a significant advancement in ride design and exemplifies the company’s growth in both its product line and its capacity.

We caught up with Kalsch to find out more.

Introducing the SCT1201

The new SCT1201 train builds on the success of Sunkid Heege’s SCT1200 train series, which has been used to replace ageing roller coaster vehicles in amusement parks around the world.

With the SCT1201, the 1200 series now has a completely new successor that incorporates all the latest standards. Notably, it has a total weight that matches that of the roller coaster vehicle it replaces.

This means that the new train requires fewer adaptations to the existing tracks, reducing costs and complexity for operators.

“The SCT1201 train generation is a completely new design with the aim of maximising weight savings while retaining the previous advantages of low maintenance and inspection costs and, of course, the excellent driving characteristics of Sunkid trains,” says Kalsch.

“This was a major challenge in terms of design and manufacturing, which, in addition to a high financial outlay, also demanded and utilised the resources and considerable commitment of those responsible for the project.

“We are proud to have achieved our goal and are also grateful to the first customers who placed their trust in us.”

Avonturenpark Hellendoorn in the Netherlands has already adopted the SCT1201 and took delivery of the new train in spring 2025. A further train is now being prepared for a client in India.

Comfortable, contemporary design

With a 20% weight reduction, the new train marks a significant milestone for the industry.

“The weight reduction means that the effort required to reinforce existing, ageing roller coaster rails is significantly lower,” says Kalsch.

“Due to changing requirements (load change standards, electrical monitoring, redundancy), the vehicles have gotten steadily heavier, which also places demands on other components, e.g., the performance of the chain lift.

“Being able to use a train that offers all safety features and complies with applicable standards without additional weight therefore has several advantages for the operator.

“Depending on the variants used, in some cases, it is even possible to reduce the minimum size of users. For instance, with the lap bar. For passengers, this bar offers significantly greater freedom of movement compared to the shoulder bar.

“The trains themselves are technically and rather puristically designed, but this has no impact on comfort. On the contrary, the modern components and new construction ensure a smooth and pleasant flow.”

Every single part of the train has been re-engineered, with the target weight achieved mathematically, or "on paper", in 2024.

“The biggest design challenge was that every single component had to undergo weight testing at some point, which meant that we had to break new ground with some assemblies, for example, plastic seats with aluminium cladding.

“Technically, the challenge was to manufacture new fixtures, keep an eye on manufacturing costs, and at the same time adhere to the very ambitious overall schedule.”

Tailored design

“Two of these new trains have been manufactured so far. The first train, delivered to the Netherlands, has now completed its first season. Another train is currently being prepared in Asia (India).

"There is also a third train project in parallel, which also involves the construction of a new train, a suspended coaster. This order is currently in production,” says Kalsch.

“Every track and every project is different and has its own 'special features.’ These must be recorded and discussed in advance with the customer and an independent third party.

"The result is usually a specification sheet with the tasks for us as the train manufacturer and any necessary adjustments and support on the part of the customer.

“Installation usually takes place outside of winter, i.e., when temperatures are in the double digits (Celsius). In addition to commissioning, it also includes training for operating and maintenance personnel.”

Furthermore, Sunkid Heege’s services span inspection, maintenance, and partial renewal of existing installations and rides. All of which are underpinned by sustainable and efficient design decisions.

“We understand sustainability to mean economical, reduced use of materials, combined with durable and easy-to-repair components. A good example of material efficiency is our new retention system with a cylinder-shaped latch/ratchet.

“Purely mechanical, low maintenance, low wear, durable, no oils,” says Halsch.

Increased output

Sunkid Heege previously built just one train per year; now it builds three. Halsch shares what’s driving this growth:

“I would like to describe it this way: Over the past 10 years, Sunkid Heege has managed to continuously expand its business with new trains.

"In addition to the 1,200 track width, a coaster was also developed for the 900 track width, in which guests sit opposite each other, a project for a Swiss amusement park.”

This new train for Conny-Land’s Cobra was developed by Sunkid Heege from initial consultation to the final TÜV approval, in close collaboration with the client.

Europe’s largest linear roller coaster, the ride was reimagined for its 10th birthday and now features a fully adjustable and damped chassis for a more comfortable ride and longer service life, targeted improvements in operation and maintenance, and the new Embrace 5 restraint system, all in addition to the signature face-to-face seating arrangement.

Growth across the Group

This increase in production has set the scene for future growth, says Halsch.

“Overall, we have a great performance in the Sunkid Group, great suppliers, and very dedicated employees at Sunkid Heege.

“I would be happy to meet the requirement of being able to produce at such a capacity on a permanent basis. This could also become a topic through the development of a new, larger Family Ride, exclusively in operator mode.”

With more than 9,500 realised projects in over 80 countries worldwide, Sunkid represents the highest quality and reliable service.

In addition to Sunkid Heege’s specialist focus on theme and amusement park rides, the group is known as the global market leader in outdoor person conveyors.

Its proven range of solutions can be found at ski resorts, theme parks, water parks and museums.

Other notable products include the Mountain Coaster, a popular summer toboggan run, known for its unique riding dynamics and sophisticated build; the Wood’n’Fun line for alpine tourism and recreational destinations; and the Moving Carpet, a new generation of conveyor solutions for water parks’ tubes and boats.

The Rocking Tower

At the Sunkid Heege subsidiary, the team is advancing roller coaster components and exploring innovative product ideas across its portfolio.

“In addition to the ongoing projects and inquiries for trains, our design department is currently focusing on the development of the new Rocking Tower, the most exciting Family Ride in the world of Sunkid, with a completely new ride concept and a distinctive design.

“We would like to expand our portfolio of operator rides with this new addition. Due to the height and movement of the ride, it is also great for park marketing.”

First announced at IAAAPA Expo 2024, the Rocking Tower lifts riders up a curved track, tilting their seats to 75 degrees before swinging them out, high into the air.

The ride is ideal for elevated locations, such as hills, skyscrapers or cruise ships, and offers extensive theming options on a compact footprint.

Worldwide reach

The company’s growth is not just fuelled by its new product development.

“We also support customers outside of their season with maintenance work,” says Halsch.

“So far, we have even been able to carry this out for some trains at our production site, which in turn brings further practical experience that also flows into new designs and further developments.

As Sunkid Heege expands its portfolio, it welcomes enquiries from new partners and collaborators.

“We are, of course, very pleased that our idea of developing a new, lighter train has inspired two first customers. The suspended coaster project is currently in progress, and I don't want to reveal too much about it at this stage, but it is also very exciting and shows that there is a corresponding demand for replacement trains.”

“In addition to the existing network and good connections to TÜV, the train projects offer opportunities for cooperation in the areas of ride control system renewal and modernisation of the brake technology used.

“In principle, Sunkid is a leading global provider of year-round leisure attractions for the whole family.

"From individual selected attractions to customised overall design, production, and turnkey implementation, Sunkid offers a wide range of products and services.

“Our innovative solutions for passenger and freight transport now move millions of people around the world.”

Find out more

Sunkid will be attending IAAPA Expo 2025 in Orlando.

Attendees can meet the team at booth #2689, on level one of the North/South Building.

IAAPA Expo 2025 is the premier event for the visitor attractions industry and will take place from 17 to 21 November.

The show floor is open from 18 to 21 November.