UK / Germany – In an era of volatility and change, some companies not only survive but continue to lead. Leicester-based BPW Ltd (the UK arm of the BPW Group, headquartered in Wiehl, Germany) is one of those companies. Truck & Bus Builder (T&BB) recently travelled to Leicester to discover how the company has retained its market leadership and what lessons the wider commercial vehicle (CV) industry can draw from its approach.

We sat down with Managing Director Neill Groves, toured the company’s modernised factory, and spoke to technical and engineering staff to better understand the foundations of BPW’s enduring success. What we found was a three-pronged strategy: continual investment in people and production, smart use of telematics and data, and unwavering commitment to aftermarket support.

Neill Groves, Managing Director of BPW Limited

Reading the market and staying ahead of it

Groves provided an overview of the UK trailer market’s dramatic fluctuations in recent years. From the post-COVID boom (fuelled by furlough spending) to today’s cooling demand, BPW has navigated each phase with calculated precision. In 2022, over 27,000 trailers were registered in the UK. By 2024, this number had plummeted to fewer than 16,000.

High raw material and labour costs, combined with a cautious economic outlook under the new Labour government, have caused many fleets to delay new trailer investments. The result: a growing second-hand trailer market and refurbishment boom. Despite this, Groves confirmed that BPW remains the market leader in the UK, crediting the company’s reputation for reliability, total cost of ownership, aftermarket support, and spare parts availability.

Investment at the heart of UK operations

During a tour of the Leicester facility, Production Manager Kevin Vaughn outlined the scale of BPW's recent manufacturing investments. Five years ago, BPW introduced a new axle assembly line as part of a multi-million-pound upgrade. The axles, engineered in Germany, are built in the UK using an advanced, computer-controlled assembly system that ensures consistency and high performance across its suspension product range.

These upgrades align with BPW’s “modular suspension principle,” which promises smoother rides, superior braking efficiency, and long-term product reliability. The company has also quadrupled its warehouse capacity, from 1,000 to 4,000 pallet spaces, and implemented a fully integrated warehouse management system. Together, these changes have enhanced flexibility, improved lead times, and reduced cross-border risks in the post-Brexit landscape.

With more than 100,000 axles assembled since 2020 and 400,000 suspensions built over the past decade, BPW’s UK arm is well-positioned to serve both the UK and Irish markets with speed and resilience.

BPW warehouse   

Aftermarket: The recipe for repeat business

BPW’s approach to aftermarket services is another critical element in its success. Given the UK's stringent trailer maintenance rules (inspections every 6 to 12 weeks), compared to just twice a year in much of Europe, access to spare parts and technical support is mission-critical for fleet operators.

To meet this need, BPW has established a comprehensive spare parts network with over 250 spare parts distribution partners. It also revamped its online parts portal, My BPW, to include technical data sheets, order histories, and compatibility suggestions. Available in 10 languages, the platform simplifies the ordering process for customers across Europe.

Perhaps most impressively, BPW has made strategic investments in training. The BPW Training and Maintenance course, now in its fourth year, is led by Technical Services Training and Production Support Engineer Nick Vernon. The course trains more than 1,000 technicians annually. “We noticed that poor maintenance was undermining even our best products,” Vernon explained. “The training programme was our answer. We’re now seeing the results—fewer servicing issues and faster repair times thanks to better-trained technicians.”

BPW training centre

Leveraging big data for telematics and compliance

Data-driven maintenance is another pillar of BPW’s strategy. Through its subsidiary idem telematics GmbH, BPW has launched a suite of smart systems to improve trailer performance, safety, and compliance.

One standout is the Electronic Brake Performance Monitoring System (EBPMS). This solution collects and analyses brake performance data in real time, helping to pre-empt failures and reduce the frequency of mandatory laden roller brake testing. The system not only enhances safety but also brings measurable cost savings by reducing downtime and testing costs.

Also in BPW’s digital portfolio is the Tyre Pressure Monitoring System (TPMS), using 36 rim-mounted sensors* to deliver real-time insights into tyre pressure, temperature, and wear. The benefits of predictive maintenance are clear: extended tyre life, fewer breakdowns, and lower fuel consumption.

ePower: A greener way forward

One of the most exciting recent developments is the UK rollout of ePower, BPW’s electric generator axle developed in partnership with Thermo King*. In response to tightening emissions regulations and the end of red diesel subsidies, the system recovers energy when the trailer is moving, enabling a carbon-neutral and quiet supply of power to refrigeration units for temperature-controlled transportation.

ePower

Sales Director Glyn Davies compared the technology to an intelligent bicycle dynamo, generating "free" electricity from braking, wheel rotation and downhill motions, which is then stored in a high-voltage battery. “The system is completely independent of the tractor and reduces energy waste,” Davies said. This solution presents the opportunity to save up to 4,000 litres of fuel annually per trailer, but also has the potential to reduce CO2 emissions by up to 10 tonnes per year per trailer.

BPW’s early trials with TIP Trailer Services and French trailer manufacturer Chereau have yielded positive feedback. “The system’s regenerative capabilities are exceeding expectations,” Groves noted. “Trailers leave with a charged battery and return with one too. That’s the kind of efficiency our clients want.”

Tip Trailer customer trial ePower

Lessons in leadership

Groves attributes BPW’s resilience to its reputation for reliability, total cost of ownership, and customer-centric ethos. The BPW Limited story is a masterclass in strategic investment, responsive innovation, and long-term vision. As economic pressures mount and technological demands grow, the company’s success offers key lessons for the wider commercial vehicle industry: invest in your brand to maintain quality and use data to diagnose problems that lead to greater product uptime for the end customer.

*These sensors can support up to 24 individual tyre sensors with the BPW idem Telematics Gateway Basic, which can be mounted on either the wheel rim or the tyre valve. These sensors transmit tyre pressure data to a receiver unit with an accuracy of up to +/- 0.3 bar. BPW TPMS can be scaled up further to include 48 sensors with the Gateway Pro option.

**Founded in 1938, Thermo King is a brand of refrigeration and heating systems primarily used in the transportation industry. The company specialises in providing temperature control solutions for a wide range of applications, including trucks, trailers, buses, and marine containers. Thermo King is a division of Trane Technologies, a global multinational climate technology company that builds products which help ensure the safe transportation of perishable goods, such as food, pharmaceuticals, and other temperature-sensitive items.

For more information about the BPW training course click here: or email [email protected].