How Modul-System designs sustainable van racking solutions
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Our Technical Director discusses sustainability, durability and smarter product design.
Behind every Modul-System solution is a team of engineers focused on one simple question: how can we build better, smarter and more sustainable products that last?
We spoke with our Technical Director about his role, how sustainability shapes product development at Modul-System and where the future is heading.
Meet the Expert
- Can you tell us a bit about your role at Modul-System and how you became involved in product development?
I am Technical Director at Modul-System and have worked with product development in the automotive industry since the beginning of the 1990s. I have been part of the Modul-System team since 2000. Over the years, I have worked closely with the development of vehicle interiors and racking systems, with a strong focus on functionality, durability, and continuous improvement.
Designing with Sustainability in Mind
- How do you focus on sustainable solutions in your product designs?
First of all, we always focus on long-term durability. A product that lasts a long time is one of the most important sustainability factors.
From there, we work heavily with weight optimisation and, where possible, we look for recycled materials that still meet our very tough requirements. Another important part is working closely with our suppliers and their manufacturing processes and energy choices, to help drive them towards a lower CO₂ footprint.
We also develop products that give our customers better conditions to manage their vehicles more sustainably. In the development of our Modul-Connect platform, a lot of work has been done to monitor how vehicles are used and how that usage can be optimised.
- How does your team stay updated on industry trends, especially in sustainability and innovation?
We follow research and development within the automotive industry through joint research projects and industry platforms. In addition, we work in close cooperation with major test and research institutes and universities.
IMAGE (Alt text: Modul-System product development with sustainable van racking)
Sustainability at the Core
- How does Modul-System incorporate sustainability into the design and manufacturing of its products?
The products must first be durable and functional for long-term use. This is one of the most important conditions for sustainability. We then carry out CO₂ analysis on both processes and material selection.
- Can you give specific examples of eco-friendly materials or processes used in your products?
A good example is our switch from conventional steel to high-strength steel (2004) and ultra-high-strength steel (2013).
Since 2013, we have reduced steel consumption by approximately 5,850 tonnes (around 450 tonnes per year), while maintaining extremely low complaint levels on shelving where ultra-high-strength steel is used. This shows that weight reduction and durability can go hand in hand.
- How do you balance durability, functionality, and sustainability in your designs?
It starts with achieving the right functionality and durability. These are prerequisites for a product to be sustainable.
- Are there particular certifications or standards you aim for when designing sustainable products?
Our development processes are according to ISO 14001, and we of course follow regulations such as REACH and RoHS. We have now also added CO₂ calculation into all development projects.
Measuring Impact & Overcoming Challenges
- How do you measure the environmental impact of your products throughout their lifecycle?
We look at CO₂ impact during manufacturing, transport, workshop operations and during use.
- Have you faced any challenges in creating more sustainable products, and how did you overcome them?
The main challenge is finding the right balance between sustainability, quality, availability, and cost.
- How does Modul-System communicate these sustainability efforts to customers?
For many years we have shared examples of CO₂ impact during product use. From 2026, Modul-System will present its sustainability work across all aspects, including the product lifecycle process concerning CO₂ and waste management, as well as CO₂ per product on quotations and order confirmations.
Innovation & Future Outlook
- Are there any exciting sustainability initiatives or innovations your team is working on for the future?
We are working together with steel manufacturers on fossil-free steel for our steel racking products.
- How do you see sustainability influencing product development trends in the industry over the next 5–10 years?
Parameters for improved sustainability have always been part of our product development and manufacturing. Modul-System products have traditionally been robust with long lifetimes.
Since 2004, low weight has been a priority throughout our development, resulting in lightweight, high-quality products. Since 2022, we have introduced recycled materials into our product range.
The main difference today is that more and more customers are actively demanding these improvements, and we will continue our work in this direction.
- What advice would you give other product developers who want to create more sustainable solutions?
Requirement specifications need to include parameters for increased sustainability from manufacturing to use, while still being balanced with quality, availability, and cost.
Practical Tips for Customers
- How can customers make the most environmentally friendly choices when using Modul-System products?
Let us know your priorities between sustainability, quality, availability, and cost. Then we can make design proposals accordingly.
- Are there any simple steps your team recommends to extend the lifespan or reduce the environmental footprint of products?
Choose high quality materials for a long lifetime and potential reuse, and lightweight products for minimal footprint during use.
Building sustainability into every product decision
At Modul-System, sustainability is not treated as a separate initiative; it is built into all product development decisions. From material selection and weight optimisation to long-term durability and fossil-free steel initiatives, every choice is guided by creating solutions that last longer, perform better, and reduce environmental impact over their entire lifecycle.
By combining engineering expertise with continuous measurement and innovation, Modul-System helps fleet managers move towards more sustainable operations without compromising on quality, safety, or functionality.
About the Author
Anders Carlsson, Technical Director at Modul-System, has worked in automotive product development since the early 1990s and has been with Modul-System since 2000. With decades of experience in vehicle interiors and engineering, he specialises in developing durable, lightweight, and sustainable racking solutions for commercial vehicles.