It’s quite amazing what motorcaravanners take for granted with their motorhomes. For example, who’s ever given a thought to how all of those electrical items operate just when we want them to?

I recently visited BCA Group in West Yorkshire, where I was given an informative tour of its three constituent companies by Sales and Marketing Director, Wayne Boyd.

BCA Group essentially comprises three firms – BCA Leisure makes wiring harnesses, control panels and power distribution units (PDUs) for leisure vehicles, while BCA Motion deals with battery boxes and smaller-scale wiring harnesses for panel van conversion manufacturers.

BCA Leisure's production facility
Inside BCA Leisure’s busy production facility

The third company, Pennine Leisure Supplies (PLS), supplies dealerships and other outlets with accessories such as lamps, kettles, cable reels, water pumps, electrical sockets and switches, as well as mains electric kits for campervans.

BCA Leisure was founded in 1981 by Wim Batist. Before buying its first premises (a former mill in Mytholmroyd, a few miles from BCA’s current location), Wim would travel to the UK with his van and trailer loaded with touring accessories on a Monday morning, drive the length and breadth of the country throughout the week, selling his wares, then return home on Saturday to reload, ready for the following Monday.

Branching out

At the time, the best-seller was Smat caravan towing mirrors, which he imported from Italy.

Wim’s father and brother ran a very successful dealership in the Netherlands, so you’d definitely say that touring was in the family’s blood.

On acquiring the old mill, as well as continuing to supply the accessories, Wim contacted some caravan brands, to see if he could supply them with 25m mains hook-up cables (leisure vehicle electrics were so much simpler back then!).

Once the business was established in the UK, Wim was approached by a manufacturer enquiring about producing 230V wiring harnesses for dealer retrofit into caravans.

Assembling a 230V PDU
Assembling a 230V PDU

About 20 years ago, it was clear new premises were needed – BCA had outgrown the old mill, and the industrial estate where they are now was in the process of development, so the mill was sold to help fund their new building.

Initially, PLS was also based at the industrial estate, but four years ago, owing to the need for larger premises, a new building was acquired, three miles away. The former PLS building is now rented by panel van converter WildAx.

BCA Group is still very much a family business. Wim Batist is the Chairman, his eldest son Harrison is in Business Development, and his youngest son William currently works in the Technical Department.

Assembling floor and sub-harnesses
Assembling floor and sub-harnesses

Both Harrison and William are seen as the core of BCA’s succession plan, as the group, which employs 160 people, moves into the future.

BCA’s first wiring harnesses were made for Bailey, but now alongside them, control systems and harnesses are made for Hymer UK and Coachman, with Swift also buying BCA components.

Cable and connectors

After outlining the history of the group, Wayne took me on a rather mind-boggling tour of BCA Leisure and BCA Motion.

I say mind-boggling because I don’t think I’ve ever seen quite so much cabling, so many different types of connector, or such huge boards where the harnesses are made. Much of this intricate work is done by hand, although there are some automated processes. Along the way, many tests and checks are carried out, and no completed harness or control unit will leave the facility until it has been thoroughly tested.

Network cabling
A complicated network of cabling

Weighty matters

Now that leisure vehicle wiring has become so complicated, there’s a weight implication. BCA works closely with manufacturers to ensure that weight (which could easily exceed 25kg for a harness) is kept to a minimum, all the while maintaining exacting quality standards.

In most cases, there’s a main floor harness with numerous ‘plug and play’ smaller harnesses being connected to that. BCA makes things as simple as possible for the manufacturers, for example by using a variety of plugs and sockets to ensure that the small harnesses only fit in the one required location, eliminating any potential errors.

As an example of just how complicated things have now become, consider this – one popular floor harness has another 25 smaller harnesses that are attached to it. A 7.5m motorhome will quite easily house 600-700m of cabling!

Floor harness
Floor harness all ready for dispatch

Such is the relationship that BCA Group has with leisure vehicle manufacturers, if a brand plans to fit a new appliance, BCA is relied on to work out which thickness of cabling is required to cope with (and exceed) the potential load, and also to avoid any possible voltage drop.

Wayne also told me that in recent times, fridge harnesses for caravans have been more challenging, because of the stop/start technology in tow cars. The problem is, if the power cuts so many times, the fridge registers a fault and stops operating on 12V. Thankfully, BCA has overcome the problem.

When making a harness, the furthest point from the power supply is the starting point, likely to be a high-level brake light, and then it will be worked back through the vehicle.

BCA Motion is where the harnesses and control systems for panel van conversions are assembled. Wayne’s knowledge of all the firm’s products was amazing. For example, he could look at a battery box and immediately say which brand of vehicle it was destined for!

Assembling battery boxes
Assembling battery boxes

Our final destination was to see PLS, a huge warehouse and distribution centre, and a very impressive operation it is, too. Items are selected from shelves by a fork-lift truck, but much of the work is now semi-automated.

The fork-lift is programmed, so although there is a driver, the vehicle knows where it needs to go and where to select the item. An impressively efficient operation. All I will add here is that it was a very long way up to the roof level!

With thanks to Wayne Boyd and Lewis Gresty (PLS) for showing me around.

After some more industry insight? Then check these out:

If you’ve enjoyed reading this article, why not get the latest news, reviews and features delivered direct to your door or inbox every month. Take advantage of our brilliant Practical Motorhome magazine SUBSCRIBERS’ OFFER and SIGN UP TO OUR NEWSLETTER for regular weekly updates on all things motorhome related.