The system creates a load-rated mounting platform for racking while avoiding penetration of the vehicle structure - something Modul-System says can introduce corrosion risks and potentially affect manufacturer warranties on modern vans.

The bonding technology, developed using high-strength structural adhesives originally used in the aviation industry, attaches structural mounting points directly to the vehicle body while leaving the underlying structure intact. The system is fully crash-tested and can be removed without permanently modifying the vehicle.

Weight reduction is another key focus for operators specifying racking for electric vans, where battery packs can significantly reduce available payload. Modul-System uses ultra-high strength steel in its racking systems, which it says delivers the same load capacity and crash performance as conventional steel while reducing overall weight.

The company points to DVSA roadside checks suggesting that nearly a quarter of vans operate overloaded, with the challenge potentially greater for electric vans due to their heavier battery packs. Alongside its racking systems, Modul-System is also promoting its Modul-Connect platform, which integrates vehicle and conversion data through Apple CarPlay and Android Auto.

The system allows operators to monitor load distribution, manage auxiliary systems and maintain digital driving records via the vehicle’s existing infotainment screen.

The platform can also integrate with the company’s e-Power 2000 auxiliary battery system, allowing drivers to control heaters, lighting and inverters through the same interface.

Modul-System recently appointed Kevin Walker as MD of its UK business. Walker joins from fleet services company TVS and brings experience in commercial vehicle engineering and operations.

“The ZEV mandate means electric vans are coming whether operators are ready or not, and the businesses that plan that transition intelligently will have a measurable operational advantage over those who don’t,” said Walker.