Montracon marks new chapter ahead of 50-year milestone
Montracon says it is entering one of the most exciting periods in its history, as it approaches 50 years of manufacturing trailers under the brand.
With new ownership from the Martin Group and a new management team led by managing director Paul Avery, the manufacturer says it is building on its established reputation for engineering, product knowledge and customer service while fundamentally changing the way it manufactures and supports its products.
“The objective is straightforward: increase production, improve quality, reduce manufacturing costs and deliver a better overall customer experience,” said Paul Avery.
“Montracon has spent almost 50 years developing its knowledge of the semi-trailer market. That experience provides a strong foundation, but the business recognises that past success cannot be relied upon to deliver future growth.
“The new ownership has brought a clear ambition to increase Montracon’s market presence and significantly increase production volumes. To achieve this, investment and operational improvement are being focused not simply on producing more trailers, but on creating a manufacturing operation capable of producing greater volumes efficiently and consistently.
“A key part of this strategy is the introduction of a much more structured approach to manufacturing.”
One of the major changes, Paul explains, is the development of modular trailer design.
“Rather than treating every trailer as an individual build, Montracon is increasingly looking at common components, assemblies and manufacturing processes that can be standardised and produced in greater volumes.
“Modularisation brings several advantages. Components can be manufactured in batches, production processes can be repeated and improved, and employees can become highly proficient in specific operations. It also provides greater flexibility when production volumes increase.
Paul Avery of Montracon
“For customers, the benefits are equally important. A more standardised manufacturing approach helps create greater consistency from trailer to trailer, while engineering improvements can be incorporated across product ranges more efficiently.”
Alongside modular design, Montracon is introducing a stronger lean manufacturing philosophy across its production operation.
“The focus is on removing unnecessary activity, improving material flow, reducing handling and simplifying manufacturing processes. A particular objective is to reduce labour content without compromising craftsmanship or product quality.
“This is not simply about asking employees to work faster. It is about designing the manufacturing process so that people can spend more of their time adding value to the product.
Better production planning, improved workstation design, standardised processes and greater use of repeatable assemblies will allow Montracon to increase output while making more effective use of its workforce.
“The result should be a manufacturing operation capable of producing significantly higher volumes from the existing infrastructure.”
Increasing production is only worthwhile if quality increases alongside it, adds Paul.
“Montracon’s transformation therefore places considerable emphasis on right-first-time manufacturing. Quality is being built into the production process rather than relying solely on inspection at the end of the build.
“Standardised components, clearer manufacturing procedures, improved controls and better communication between engineering and production are all helping to reduce variation.
“The objective is simple: trailers should leave the factory correctly built, consistently finished and ready to perform for the customer from day one.”
Recent innovations include Montracon’s Lightweight Box Van. Its reduced weight increases available payload, says the manufacturer, and can also help cut fuel consumption which in turn supports lower CO₂ emissions.
For high‑mileage fleets, even small efficiency gains accumulate: Montracon estimates that a 200‑trailer fleet could save around £482 in fuel and 739kg of CO₂ per trailer each year, adding up to more than £675,000 and over 1,000 tonnes of CO₂ across a seven‑year life.
The trailer uses a new modular design to reduce weight while supporting easier repair and future development.
“For operators who need a reliable enclosed trailer solution with improved efficiency at its core, this new development offers a strong option,” said Montracon.
