Logistics firm Neovia has introduced GPS tracking across thousands of roll cages and tote boxes after an estimated £320,000 worth of reusable equipment was put at risk of going missing each year.
The technology, supplied by Sensolus and deployed by Peak Technologies, has been introduced at one of BMW Group UK's logistics operations, where Neovia manages the distribution of vehicle parts.
Around 40% of the company's returnable asset fleet was disappearing from the returns cycle annually, with individual roll cages costing between £350 and £500 to replace.
The problem arose as vehicle parts travelled between Neovia's facilities and more than 230 dealerships across the UK and Ireland, often using third-party transport providers.
Previously, barcode systems recorded when equipment left a warehouse but offered little visibility once it entered the wider distribution network.
This made it difficult to establish where roll cages and tote boxes had gone missing or who was responsible for returning them.
BMW Group UK's requirement for GPS-based tracking as part of a contract renewal prompted Neovia to seek a new asset management system.
Following a tender process launched in December 2025, the company selected Sensolus technology, with Peak Technologies providing installation, software and ongoing support.
Justin Collingwood, general manager at Neovia, said the lack of visibility had been a longstanding challenge.
“While our barcode systems could confirm when assets left our warehouse, they provided little visibility beyond that point.”
He said the new system had improved accountability across the network, helping reduce losses and strengthen operational efficiency.
The rollout covers a fleet of approximately 5,000 assets, with the GPS trackers installed directly onto existing roll cages and tote boxes.
Full implementation was completed within four months, without requiring major changes to warehouse infrastructure or existing processes.
A further batch of 3,500 tote boxes and 1,500 roll cages was subsequently prepared for tracking within four to five weeks.
The compact Sensolus 1110 devices can be attached to roll cages using adhesive pads and rivets, allowing equipment to be monitored as it moves through the distribution network.
Geofencing technology records when assets arrive at or leave dealership locations, providing timestamped information about their movements.
The trackers can also detect when a roll cage tips during transport, helping operators identify potential problems involving valuable vehicle components.
Anthony Fulgoni, solution consultant at Peak Technologies, said the straightforward installation had been a major advantage.
“The stick-and-track approach is deliberately straightforward. There's no infrastructure to install, no complex integration project, and no disruption to existing operations.”
According to Neovia, the introduction of GPS tracking has already resulted in the return of numerous roll cages previously considered lost.
The company says greater visibility has encouraged stronger accountability among those handling its equipment, reducing the need for active recovery efforts.
Beyond locating missing assets, the system is providing information on how long equipment remains at individual sites, warehouse throughput and movement patterns across the network.
These insights are being used to support logistics planning and identify opportunities to improve operational performance.
Neovia also reports environmental benefits from reducing unnecessary equipment replacement and cardboard waste.
Farid Khadir, UK channel manager at Sensolus, said the technology had delivered benefits beyond recovering missing equipment.
“What they've ended up with is a real-time operational picture of their entire supply chain that they simply didn't have before.”
The companies say the rollout demonstrates how GPS tracking can help logistics operators reduce asset losses, improve accountability and gain greater control over equipment moving through complex distribution networks.