Less is more: Humbaur focuses on lightweight construction methods optimised for payload

At this year’s IAA TRANSPORTATION, taking place from 15 to 20 September 2026, Humbaur GmbH will be showcasing its lightweight vehicle bodies for dry freight, featuring a payload-optimised floor. Thanks to sandwich panels with a GRP outer layer and a specially developed plastic honeycomb floor, valuable kilograms can be saved in logistics transport, resulting in increased payload capacity.

In an industry where efficiency, environmental sustainability and cost-effectiveness are key factors, lightweight construction of commercial vehicles is becoming increasingly important. Humbaur’s FlexBox vehicle body, featuring an aluminium subframe and sandwich pan with a glass-fibre-reinforced plastic (GRP) outer layer, and – thanks to the plastic matrix with embedded glass fibres – saves around nine kilograms in weight per square metre compared to sandwich panels with a galvanised steel outer layer, whilst remaining robust, tensile-strong, rust-free and durable. This means that a wide range of transport requirements can be met thanks to the maximum payload – whilst maintaining a maximum gross vehicle weight of 3,500 kilograms.

LAMIpanel: Payload-optimised plastic honeycomb floor

A newly optimised plastic honeycomb floor also enables a further 50 kilograms to be saved, thereby increasing the payload accordingly. This means that Humbaur has achieved a 50 per cent weight saving in relation to the floor. To optimise the plastic honeycomb floor, the trailer manufacturer from Gersthofen in Bavaria teamed up with Lamilux, its long-standing partner and supplier of sandwich panels for its FlexBoxes. Through a series of extensive long-term test procedures, which included around 15,000 loading and unloading cycles, the 15-millimetre-thick LAMIpanel plastic honeycomb floor demonstrated significantly better compressive strength and abrasion resistance compared to the previous screen-printed panel, which was also 15 millimetres thick. In everyday use, this primarily means that the interior of the FlexBox can be easily cleaned using a steam cleaner without the risk of moisture penetrating the floor and thereby shortening its service life, as well as increased robustness when handling heavy loads.

The plastic honeycomb floor is formed using a gentle manufacturing process involving heat and no adhesives, and the material itself is recyclable.

At IAA TRANSPORTATION, Humbaur is showcasing the floor in a FlexBox Dry fitted to a MAN TGE chassis.

Both Humbaur and Lamilux are family-run businesses, manufacture in Germany and are distinguished by their many years of experience and their high standards of quality.

Humbaur FlexBox

Humbaur vehicle bodies stand for innovation and versatility in distribution transport. This is because the bodies are custom-built to fit a wide variety of commercial vehicle models. Drawing on the extensive range of accessories, the vehicle can be customised with features such as a sandwich roof, a side door with a step, reversing camera systems and various access options. With insulated walls, doors and floor, it is also possible to transport goods in a refrigerated or even frozen state. All variants are weight-optimised to maximise payload capacity. This means that the FlexBox can accommodate roll containers, E2 crates and pallets alike.

Come and see the Humbaur FlexBoxes in person at the outdoor exhibition area of IAA TRANSPORTATION at stand numbers R57 and S17, as well as at the partner stands of IVECO, MAN Truck & Bus and Renault Trucks.

Images

You can find images of the exhibition vehicles here.

Please credit Humbaur GmbH as the source of the images.