Heavy duty, feather-light

Long distances, heavy loads and demanding road conditions define daily life in the South African transport market – especially in the agricultural sector. From the vast plains of the Eastern Cape, where rugged terrain and oversized loads are part of the job, an inconspicuous piece of German engineering is making a quiet revolution. The ultra-light trailing arm – BPW’s “LightTube” – is designed to eliminate excess deadweight and convert every kilogram saved into revenue-generating payload. For JAN MEYER VERVOER, one of the region’s leading freight carriers for maize and grain, efficiency is measured not in abstract figures but in tonnes delivered, litres of fuel consumed, and South African Rand banked.

Road freight economics in South Africa are driven by volume and total vehicle weight. The standard workhorse: the B-Double – a combination of a tractor unit and two connected semi-trailers – can legally operate at a gross vehicle weight of up to 56,000 kg, far exceeding limits seen in Europe. Commonly referred to as “interlinks,” these truck configurations use specialised fifth-wheel couplings to connect the trailers. In this setup, every unnecessary kilogram of trailer weight translates into lost payload – and therefore, lost revenue – especially in the low-density grain transport business.

BPW’s engineers began with a deceptively simple challenge: how to create a suspension component that’s robust where strength is essential – yet as light as nature allows? Their answer: bionics – the study of biological constructs that optimise weight and strength. Taking inspiration from bone structures, the LightTube trailing arm is crafted from an innovative mix of materials and formed as a hollow profile. Like a femur, it provides high flexural strength and durability, while minimising material use and weight. The result is a patented component that balances uncompromising stability with remarkable lightness. This is a measurable advantage in the everyday life of a fleet operator such as JAN MEYER VERVOER:

The fleet operator emphasises that the lightweight Airlight II air suspension pays off particularly well in South Africa. The economic case for the LightTube is compelling – particularly in agriculture, where market prices for grain and maize can be volatile and margins are fiercely contested: 

• 42 kg more payload per trip: Over a year, this translates into substantial additional revenue, especially in bulk transport.
• Lower fuel consumption: On long hauls, even modest weight savings reduce rolling and acceleration resistance, noticeably cutting fuel use – a key factor in a country where diesel prices are high.
• Rock-solid reliability: The spring is not only lighter, but also remarkably durable and low-maintenance – crucial for the rugged terrain beyond South Africa’s main highways.

Even though legal gross weights in Europe are lower, the underlying principle remains the same: less vehicle weight means greater payload, reduced wear and tear, and lower cost per tonne. The advantages demonstrated under South Africa’s demanding conditions speak for themselves – and have set the stage for a wider rollout: BPW is now establishing the LightTube trailing arm a standard configuration for 9t Airlight II running gears globally.

“The success of BPW’s Light Tube trailing arm in South African agricultural logistics is a practical example of how targeted technical innovation can increase both the cost-effectiveness and robustness of a fleet,” says  Customer Support and Training Manager Zehraan Rassool from BPW Axles in South Africa. “Vehicle design is becoming a strategic lever – not only in regions where transport routes are long and operating conditions are tough. As seen with JAN MEYER VERVOER, it can make the decisive difference in the competition for markets and margins.”