Modul-System

Van racking systems for service vehicles

Modul-System

We can convert your empty van into a fully functioning service vehicle with our modular van racking systems and van shelving. We offer a complete van conversion service, which in addition to indispensable van racking can include modular floors and van liners, vehicle electrical systems, accessories, vehicle graphics and livery.

We fit racking solutions to a wide range of vans and commercial vehicles including LCVs, MCVs and pick-up trucks. No matter which business sector you operate within, or what you drive, we have a van racking system to suit your business, whether for a single van or a fleet of vehicles. 

 

Benefits

  • Modular racking systems with short installation time.
  • Lightweight racking allows increased load capacity or lower fuel consumption.
  • Good for the environment; lower fuel costs equate to lower CO2.
  • Greater flexibility for your day to day business with customized van storage solutions.
  • Extended functionality with accessories to create a more efficient workspace.
  • Robust, durable and collision safe vehicle racking conversions.
  • Non-intrusive racking installation to protect the vehicle’s residual value.

Customized as standard 

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Our van racking solutions are based on modules, and consequently extremely flexible. You can create a completely customized solution based on standard products, and the unique, patented T-track acts as an interface to other modules.

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All products have been designed to withstand the forces they will be subjected to in a moving vehicle, which generally means a safety factor of three compared with a stationary vehicle.

Our products are thoroughly tested for load capacity and collision strength, and comply with the European TÜV standard. Their dimensions and the choice of materials are chosen to maximize load capacity while complying with demands for low fuel consumption and environmental impact.

 

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LIGHTWEIGHT AND ROBUST

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Modul-System is vastly experienced in producing lightweight steel racking systems. We were the first in our industry to introduce high strength steel (HSS), and later ultra-high strength steel (UHSS), into our products. By using this high-tech material, we have been able to reduce the weight of our products even further, while the solutions remain extremely robust and collision-safe.

A lighter weight racking system provides many benefits, including increased load capacity, lower fuel consumption, and reduced emissions.

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UHSS - THE ULTIMATE MATERIAL FOR VEHICLE RACKING

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On the market today, there are many different steel qualities with different properties. The optimum steel for the job depends on what the product will be used for, and which properties it should have.

Modul-System’s ultra-high strength steel (UHSS) is four times stronger than mild steel. Its extreme strength enables constructions in substantially thinner steel plate, which means lighter weight products.

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UHSS - THE ULTIMATE MATERIAL FOR VEHICLE RACKING

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On the market today, there are many different steel qualities with different properties. The optimum steel for the job depends on what the product will be used for, and which properties it should have.

Modul-System’s ultra-high strength steel (UHSS) is four times stronger than mild steel. Its extreme strength enables constructions in substantially thinner steel plate, which means lighter weight products.

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However, designing in ultra-high strength steel is not as easy as it might sound. To get good rigidity with thinner steel, it normally requires modifying the shape.

For example, the Modul-System shelves have a rolled edge that counteracts flexure (bending). This patent-pending design allows for a weight reduction of up to 40% compared with the equivalent shelf in mild steel.

 

Material comparison

Are you struggling with payload? Considering switching to another material to reduce the weight of the racking system? If so, you might want to reconsider.

We have carried out a direct comparison between the current Modul-System racking and what the equivalent modules would weigh if produced in another material. Sustained load capacity was a prerequisite.

In conclusion, the system would weigh approximately the same if produced in aluminum, and would be considerably heavier if produced in plastic/composite or mild steel.

 

  Aluminum Mild steel HSS UHSS
Density  2.7 kg/dm3 7.8 kg/dm3 7.8 kg/dm3  7.8 kg/dm3
Strength 70-150 MPa 200 MPa 350-500 MPa 700 -1100 MPa
E-modulus  70 GPa  210 GPa 210 GPa 210 GPa
         
Relative density 1 3 3 3
Relative strength 1 1,5-2 3-4 4-6
Relative e-modulus 1 3 3 3
Relative impact resistance 1 2 2,5 3

 

All steel, regardless of strength, has identical density and e-modulus. This means that products of the same size and shape, whatever the grade of steel, will weigh as much and bend as much when loaded. The difference between them is their strength, where an ultra-high strength steel can bear up to 6 times the load of an equivalent product of aluminum. 

 

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INCREASE YOUR PAYLOAD OR REDUCE YOUR COSTS

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Increased payload and a robust solution. These are two factors our customers often mention when discussing their overall expectations of a conversion. Modul-System's racking solutions are produced from ultra-high strength steel, which makes them both lightweight and durable. Reducing the total weight of our vehicle conversions is of paramount importance to us. Continue reading to find out why.

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Want to increase sales?


Number of vehicles in the fleet: 400
Potential increase in sales: € 2.2 million per year

Businesses that want to increase sales must focus on value-generating activities. Travel to retrieve materials and equipment does not belong in this category. With a lighter weight conversion, you can load more into the vehicle and the travel time saved can be transformed into chargeable time instead.

If a fleet of 400 service vehicles can charge for an additional 20 minutes per vehicle and day thanks to the increased load capacity, this means, at an hourly rate of € 75, a potential increase in net sales of € 2.2 million per year*. 

* Example based on 220 working days per year.

 

Want to reduce costs?


Number of vehicles in the fleet: 400
Potential cost savings: almost € 50 000 over 3 years

Not everyone will want or need to take advantage of the increased load capacity offered by a lightweight conversion. But there is still money to be saved on reduced fuel costs.

For a fleet where the average racking system weight is reduced by 44 kg (from 144 kg to 100 kg), fuel consumption can be reduced by 0.1 liters/100 km*. If each vehicle on average drives 35,000 km per year, the fleet consists of 400 vehicles, and fuel costs € 1.4 per liter, the business can save almost € 50 000 over a three-year period.

* In the example, it is assumed that the vehicle fully laden consumes 9.4 liters/100 km. It is also assumed that fuel consumption is reduced by 0.18 liter/100 km per 100 kg weight reduction. Source: www.worldautosteel.org/projects/determination-of-weight-elasticity/

 

Care about the environment?


Number of vehicles in the fleet: 400
Potential reduction in CO2 emissions: 87 tonnes over 3 years

Reduced fuel costs are not the only benefit of reducing the total weight of the vehicle. Lower weight also means lower COemissions.

For the above example, where the weight of the conversion was reduced by 44 kg and each vehicle on average drives 35,000 km per year, CO2 emissions would be reduced by up to 87 tonnes over a three-year period*.

* In the example, it is assumed that the vehicle fully laden consumes 9.4 liters/100 km. It is also assumed that 1 liter of fuel corresponds to CO2 emissions of 2.62 kg. Source: www.fleetnews.co.uk/costs/carbon-footprint-calculator/

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Accessories

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The Modul-System accessories are innovative products that have been specifically developed for use with the Modul-System range. By adding accessories, you can extend the functionality of the racking system and make your workspace even more efficient.

Customize a kit for your van

We are offering a range of pre-designed kits, tailor-made for each vehicle.  
Please select your vehicle below to view the solutions available.

 

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