Leyland Trucks has completed its £5.1 million Zero Emissions Truck Testing Automation (ZETTA) project, a two-year initiative aimed at strengthening battery electric vehicle (BEV) manufacturing in the UK.
Backed by joint government and industry funding via the Advanced Propulsion Centre UK (APC), the project was launched in 2023 in partnership with HSSMI and Expert Technologies Group. Its outcomes include new automated assembly lines, enhanced safety processes, and the digitisation of the company’s 86-acre Leyland site.
According to Leyland Trucks, the ZETTA programme has introduced two advanced assembly lines for electric drive modules and high-voltage battery systems, as well as automation in safety-critical tasks such as protective earth and leak testing, and fitting Main Service Disconnect (MSD) units. These steps are intended to improve both efficiency and operator safety.
The digitisation of the Leyland site has also allowed the company to test new processes and equipment virtually before installation, reducing downtime and accelerating innovation. In addition, a feasibility study into high-voltage battery pack assembly has outlined a roadmap for future production scaling.
Phil Jones, Managing Director at Leyland Trucks, said the project has “strengthened [the company’s] battery electric vehicle production capabilities and created a solid foundation to meet future demand.”
Expert Technologies Group stated that the automation and digital-testing technologies developed through ZETTA could support production of 30 BEV trucks per shift, while HSSMI highlighted the role of “factory digital twins” in enabling Leyland to virtually commission new processes and optimise production.
The APC described the ZETTA project as an example of how collaborative initiatives can expand the capabilities of UK-based OEMs and suppliers in zero-emission truck manufacturing.
The project contributes to the UK government’s net zero targets by embedding automation, safety, and digitalisation into BEV production, while also providing a potential model for the wider commercial vehicle industry.
