Built for 5-Gallon HOD Fleets

Deliver up to 60% more
5-gallon bottles per shift

KTLC roll-up door bodies reduce loading time and improve payload efficiency through a fully welded aluminium structure designed around your operation.

Get my fleet TCO analysisSee how roll-up door works

Built around your daily delivery needs, routes, and matched to your current racks.

90 → 192
Bottles per vehicle Documented · Germany
Since 1994
Specialist experience
28 Countries
HOD fleets served
KTLC roll-up door aluminium body being loaded by forklift

How it works

Load faster. Deliver more bottles. Maximise payload. Stay on the road.

A smarter delivery system: load faster, unload easier, deliver more. Each body is designed around your racks, routes, and the way your team actually works.

Immediate access through roll-up doors

Immediate access through roll-up doors

Roll-up doors give instant access to each bay. The driver reaches the right bottles without climbing in or working in awkward positions that lead to injury. 4 min forklift loading vs 30 min manual, documented Germany fleet.

Maximum legal payload per route

Maximum legal payload per route

The fully aluminium body keeps weight low while maintaining the strength needed for demanding daily distribution. 192 bottles per 7.5t vehicle, up from 90 in documented operation.

Built to last. Minimal servicing.

Built to last. Minimal servicing.

From 1 -0 repairs in 8 years of documented fleet use. Only three components require routine maintenance. Our fully welded aluminium bodies are built for intensive daily 5-gallon distribution. KTLC bodies remained in daily service for eight years without body repairs. Confirmed Austria 5-gallon fleet.

BUILT ON PARTNERSHIP

Trusted by leaders in 5-gallon water delivery

The challenge

Your team can deliver more. Give them a vehicle built for the job.

vans and standard bodies can limit the number of bottles delivered each day. Depot returns take time, manual loading delays the start of each route, and a heavy body reduces the payload available for bottles.

  • Depot returns for reloads Two return trips per shift can cost around 1.5 hours - lost in traffic — capacity that could go to delivery.
  • Manual or mix loading 30 minutes every morning, adds up to 2.5 hours a week— lost time and effort your driver could spend on deliveries.
  • Payload limits restrict what each vehicle earns Every kg of unnecessary body weight is a kg of product you cannot carry on that route.
  • Body breakdowns. A truck in the workshop cannot deliver bottles. Your team must rearrange routes and pay for a replacement vehicle.
Your team can deliver more. Give them a vehicle built for the job.

FITS THE BEST CHASSIS

Designed around your chosen chassis

The chassis is chosen by you. We design the body around it, taking into account wheelbase, technical specification, payload needs, and homologation requirements.

Each body is developed individually. The body fits your operation rather than forcing your team into a standard commercial setup.

Certified for OEM cooperation · CoC available for DAF, MAN, IVECO and Mercedes-Benz. Final fit depends on chassis specification, body layout, and homologation requirements.

Full technology details
Designed around your chosen chassis
Built for multi-drop delivery

Every detail designed around the way your 5-gallon fleet actually works.

KTLC Europe — KTLC Europe — building bodies for water delivery fleets since 1994.
Request fleet and route review →

Proven on 5-gallon distribution

Real fleet results. Measured in daily operation.

Taken from documented 5-gallon delivery operations. Results depend on route model, loading method, and vehicle configuration.

90 → 192
Bottle capacity per vehicle
Germany · 7.5t Mitsubishi Canter · 5-gallon water
30 → 4 min
Loading time per shift
Manual loading before vs forklift loading after
0
Repairs in 8 years of intensive daily use
Austria · 5-gallon operation · 7,5t chassis
€32,000
Resale value retained after 8 years
Austria · 5-gallon fleet · Confirmed resale

Case study 01 · Germany

More deliveries per driver, per shift. Same zone. Same day.

Van-based model limited volume, required reload returns, and created wasted time in loading and traffic.

More deliveries per driver, per shift. Same zone. Same day.
5-gallon water distribution 7.5t IVECO Daily · 6.5 bays · 192 bottles · Poland
Before: van-based operation
70–80 bottles per van, hitting the capacity ceiling before route completion
2 reload returns per shift, around 1.5 hours lost in traffic
2× 30 min manual loading at the depot, 1 hour of unproductive time daily
Driver leaves the delivery zone to reload, so route productivity drops
After: KTLC roll-up door body
192 bottles delivered per vehicle in a single 8-hour shift
Driver stays in the delivery zone all shift, with no reload returns
4-minute forklift loading at shift start, so the driver is ready immediately
Higher route productivity and lower fuel cost per delivery
Results specific to this route model, loading setup, and vehicle configuration. Ask us to review your fleet. Request Fleet Review

Fleet evidence

More than a claim - documented record.

Verified in real fleet operations with named clients, documented service histories, and confirmed financial outcomes.

Fraikin · Long-term fleet partner
Fraikin · Long-term fleet partner
25 years of cooperation and a proven 8+8 financing model.
Bodies produced in 2007 are only now being retired from active service, demonstrating approximately 20 years of real operational life. The 8+8-year financing structure: one body, two chassis, one long-term asset.
20 yrs
Documented body life in active fleet
25 yrs
Continuous cooperation with Fraikin
Culligan Germany · Beverage distribution fleet
Culligan Germany · Beverage distribution fleet
8-year-old bodies refurbished and returned to service.
Eight KTLC bodies delivered in 2018, refurbished and returned to service. Aluminium structure in excellent condition. Resale value confirmed at €32,890 net per body.
8 yrs
High-intensity daily operation before refurbishment
€32,890
Net resale value confirmed after 8 years

The multi-chassis lifecycle concept

One body. Up to three chassis lifecycles.

When a chassis reaches the end of its service life, a KTLC body can be refurbished and fitted to another suitable chassis. Designed for up to 20 years of use, it lets fleet operators spread the body investment over more years and vehicles.

1 purchase

Years 0–8: First chassis cycle

Body installed. Intensive daily distribution. No body repairs documented over 8 years.

3 chassis

Around year 8: Refurbishment and transfer

Chassis retired. Body inspected and refurbished. Only 3 components require service.

maximised investment

Years 8–20+: Second and third cycles

Body continues on new chassis. Around 50% cost saving vs full replacement. Resale value.

How the project works

From route review to road-ready in 4 steps.

Each body is built around your needs and your daily distribution model. We analyse your routes, loading method, and rack type, then move through body configuration, production, and delivery. A successful delivery vehicle takes close cooperation between you, the chassis manufacturer and KTLC. Together, we match your daily operation, the chassis specification and the body design before production begins.

Step 01

Fleet and route review

We analyse your delivery model, routes, loading method, and rack format. This review forms the complete basis for the body specification, nothing assumed or estimated.

Step 02

Body design

Bay design, access logic, payload capacity, and vehicle fit matched to your daily needs. Every drawing developed individually, not adapted from a standard template.

Step 03

Body production

Body built and prepared for homologation. What is designed is built exactly as specified, no substitutions, no shortcuts.

Step 04

Ready for operation

Installation at our plant or locally at a service partner anywhere in the world. Ready for daily use from day one.

Questions operators ask

Key questions before changing body concept.

The point is not a one-size-fits-all body. The point is to see whether the design fits your route model, rack format, and delivery workflow.

Yes. Each body is designed individually around your current rack system, route model, and daily workflow. Bay dimensions, including width and height, are matched to your needs, so the body fits your operation rather than forcing your team into a standard commercial body setup.

Yes, if your delivery model would benefit from higher route capacity and a more efficient loading process. In several 5-gallon operations, the biggest gains came from moving beyond van limits, reducing return trips for reloads and increasing delivery output on every shift.

The chassis is chosen by you. We design the body around that chassis, taking into account wheelbase, technical specification, payload needs, and homologation requirements. We currently support MAN, Mercedes-Benz, IVECO, DAF, Renault, Ford, and other major brands.

Service is simple. In normal daily use, only three elements require standard maintenance: the roll-up doors, the locking system, and the side steps. Most local service partners can be trained to maintain and repair the body.

Yes. Our bodies are designed in line with chassis manufacturer guidelines. Homologation can be handled by us (through IVA, or CoC for larger orders) or locally, depending on the market and project requirements.

The body changes the way the route works. It helps the driver work faster and more easily through quick forklift loading and immediate access to every bottle during delivery. It also increases payload, allowing more bottles to be delivered on each route, while reducing wasted time and fuel caused by return trips to the depot for reloads.

Who we are

30 years of experience. Proven technology.

Established in Poland in 1994 as HESSE Europe, part of the Canadian PARCO Hesse group, and managed by the Lenarczyk family from the start, we have spent over 30 years adapting aluminium delivery bodies to European chassis and fleet operations.

Trusted by distribution fleets, we turn our expertise into lasting value for your operation: precise chassis integration, efficient loading, safer driver access and durable construction. Every body is built around your distribution needs — helping you deliver more today and protect your investment for years to come.

AquaAwards 2025 · 1st Place — Sustainability Leadership · Watercoolers Europe · Milan

  • 1994 Founded · Kraków, Poland
  • 28 Countries with fleet expertise
  • 18–20 yrs Documented body service life
  • 30 yrs Fraikin, longest fleet partner
Meet the team and our full history →
30 years of experience. Proven technology.
Request a review
Tell us about your route model and current setup.

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Trusted by
Fraikin · 30-year cooperation Culligan Austria · Beverage fleet ITS & DEKRA DIN EN 12642 XL certified OEM cooperation · MAN, Mercedes, IVECO, DAF AquaAwards 2025 · 1st · Sustainability Leadership