Penso British Engineering

Blue Ocean Home Delivery Pods


Last mile logistics fleets face a number of challenges including:

  • Increasing demand for home deliveries
  • Costs – vehicle, fuel and drivers
  • Vehicle damage
  • Driver shortages
  • Vehicle security
  • Health and Safety
  • Tighter environmental legislation
  • Need to reduce congestion

Ultimately, they need to solve all of these issues while still remaining commercially viable.


Using our experience of working with carbon fibre in the automotive and aerospace sectors, we have developed a range of ultra-lightweight bodies for 3.5-tonne commercial vehicles which we believe represent the future of last mile logistics.

Our Blue Ocean Home Delivery Pods can be adapted to a wide variety of applications for both temperature controlled and dry freight fleets, including supermarket delivery vehicles, white goods distributors and parcel businesses.

Crucially, Blue Ocean Home Delivery Pods have the potential to increase payload by up to 50% and tote capacity by as much as 30%.

Put simply, a 3.5-tonne vehicle with a Blue Ocean Home Delivery Pod can carry the same weight of goods in two journeys that a traditional vehicle delivers in three.

The cost-effective lightweight composite solution we have developed has been the result of more than 10 years of research and a £16.3 million investment – half from Penso and half from government matched-funding via the Advance Propulsion Centre (APC) and Innovate UK.

A large proportion of this investment has been in developing a flexible automated robot assembly line housed in a brand new 50,000 ft2f facility in Coventry which can produce a finished body every 42 minutes.

That’s because the panels for our carbon fibre pods – which each incorporate 5,000 recycled plastic bottles – are press formed and take just minutes to construct, making the end product a commercially viable alternative for home delivery fleets for the first time. Typically, carbon fibre panels have taken hours to manufacture in an autoclave, pricing the solution out of the fleet sector.


We have launched our Blue Ocean Home Delivery pods with two body types initially. The Blue Ocean e-Grocery Pod features a triple compartment temperature-controlled pod for grocery home deliveries, offering the ability to carry 140 totes versus an industry standard of between 110 and 120. The Blue Ocean e-Delivery Pod is an ultra-lightweight Luton van, offering 19m3 of load space and an interior height clearance of 2.4m.

Both pods have been configured for a 3.5-tonne medium wheelbase, front-wheel drive, Mercedes-Benz Sprinter.

The significant increase in payload we have achieved, combined with a truly aerodynamic design, improved functionality for drivers, compatibility with diesel, electric and hybrid chassis plus an unparalleled 10-year structural warranty offers huge cost-saving potential for home delivery fleets.


Do you have an engineering project that could benefit from our wide-ranging expertise and proven track record?