Pelipod Case Study

Power solution for parcel box access control


iPRO Manufacturing Solutions Ltd




Pelipod Distribution Locker 

Size of project:

3,000 units initially


Scope of Service:

  • New Product development
  • Design modifications
  • CAD
  • Prototyping
  • Sample Provision
  • Bespoke parts manufacture
  • Testing

  • Supplier research and selection
  • Parts procurement
  • Quality control
  • Electro-mechanical assembly
  • Logistics planning
  • Delivery

The situation

iPRO, a leading sourcing and manufacturing solutions provider, approached NSF Controls with a multi faceted actuation challenge. iPRO offers a range of services that spans the entire manufacturing process, addressing customer requirements throughout the product life cycle and was working with a company called Pelipod.

Pelipod was set up in 2013 to launch a new design of standalone secure delivery lockers. The lockers offer the additional advantage of internet connection for centrally monitored proof of delivery and collection.

The challenge

Collaborating with the client there were three key elements to consider when designing the actuation solution for the locker unit’s initial manufacture.

  • Firstly, the units were battery powered - this meant the locker could operate anywhere, regardless of where it was placed with no mains or Wi-Fi required.
  • Low power consumption was essential to ensure longer life,
  • and, with the unit designed as a slam shut device, the power solution for this parcel box’s access control had to ensure this was accommodated.

The solution

A low energy solenoid was sourced to suit the battery operation requirement for low power consumption. Having identified an open frame solenoid from the Far East as a basis for the application, NSF Control’s application engineers made slight adaptions to ensure it was fit for purpose. Design modifications were made to the plunger and push rod assembly, resulting in the completed customised solenoid.

Delivering a low energy solution

Particular consideration was given to avoiding circumstances that would lead to power wastage. For example, a spring exerting an unnecessary side load would result in higher power use.

Throughout the process, NSF Controls engineers were mindful of manufacturing cost, providing an innovative option that was not too costly to produce or replace, given the nature of the application conditions.

The results and future

Secured battery life

Crucially, the solenoid helped to secure a battery life of one year for the Pelipod locker product.

Success of product led to sale of Pelipod

The product was so successful that BT bought Pelipod in September 2016, becoming part of BT’s Wholesale and Ventures Division.

BT is using the Pelipod network for its own internal business needs and to service third parties. The Pelipod locker roll-out began in December 2016 and will be placed at approximately 500 of BT’s sites nationwide, eliminating the need for engineers to travel the long distances required to collect equipment from BT’s forward stock locations or distribution centres.

Pelipod is continuing to sell its solutions outside of BT, in the UK and abroad and developing the B2B market is the main focus of the business now.

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To find out more, please contact our specialist Design & Engineering Team +44 (0)1535 661144 or email 

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