Nova on winning streak

You’d think winning back-to-back caravan manufacturer of the year awards would allow a company some time to sit back and bask in the glory…

But not Melbourne-based Nova Caravans, which is midway through a 'future-proofing' transition from traditional ‘stick and tin’ construction to more modern full sandwich panel production of its popular range of full-height touring, off-road and slide-out caravans.

One of the ‘fast movers’ in the Victorian caravan industry, the Campbellfield, Victoria-based manufacturer last month was recognized for the second successive year by the Caravan Industry Association Victoria, as its caravan manufacturer of the year, pipping the other finalists Concept and Crusader.

The award, which recognizes excellence in a number of areas including marketing, customer service, business growth, professional development, workplace health and safety and environmental and community support, is the latest in a line of business awards picked up by Nova over its relatively short 12 year history.

Starting in a small rented shed in 2006, Robert Cataldo, his wife Louise and small staff built 33 caravans in their first year, 100 in the second, and are now on track to produce close to 400 by the end of this year.

Earlier this year Nova converted its popular entry-level Metrolink caravan from timber frame/aluminium cladding to aluminium sandwich panel wall construction, with the Bravo and Family Escape models also now benefitting from the smooth new, lighter weight but more structurally rigid construction.

The off-road Terra Sportz caravan is also benefitting from a new one-piece honeycomb floor, and the plan is to have Nova’s entire range built using full sandwich panel and roof construction by late-2019.

As well as the claim of being more resistant to sun damage than a fibreglass finish, the smooth aluminium sandwich panels also allow weight reductions of up to 100kg depending on model.

“When we won last year we had already started research on sandwich panels, and we were starting to focus on lightweight construction, because that’s where the industry is going to move, building lightweight caravans,” explained Nova Caravans marketing manager Ana Maria Osorio.

“(We can shed weight) through the sandwich panels, and also the way we build the furniture, including using new benchtop materials, which will help make the vans a little bit lighter."

Nova describes the new 'Pro-Al' panels, which are similar to that used by Avan and newcomer Willow RV, as "the future of caravanning", and they will also allow the company to introduce a new automotive-style wiring loom across its range, which will further improve production efficiencies.

As well as offering a three year warranty (fast becoming the new industry norm), Nova has introduced a 24/7 online ‘chat’ service that also includes roadside assistance for travelling owners, and is rolling out customer loyalty and buyer referral incentive schemes.

With 70 staff, Nova’s current 3000sq.m factory which opened in 2013 is also a ‘test bed’ for the latest industry drive to improve employee training and staff retention across the industry.

“Nova is working closely with a Workforce Training Steering Committee in developing modules in all departments across the factory floor to enable our staff to receive a Melbourne Polytechnic Certificate upon completion,” Osorio said.

“The Workforce training implemented and run on-site at the Nova factory will will set a base guideline for the whole industry on how to manufacture caravans.”

Nova has also been a pioneer of new designs and technology, from ground-breaking vans like the Nikpol cusom van, to different layouts such as the Workabout and the early adoption of new innovations like RV Wi-Fi.

“We want to keep improving, and that’s why we'll be adding another building on the vacant land next door to the factory, to set up an R&D centre as well as a new service and repair centre,” she said.

Nova keeps in regular contact with the RV community, via a monthly e-newsletter with 60,000 subscribers, competitions run on social media, and getting involved with events run by the various Nova owners’ clubs.

Keeping up with the latest trends, a recent tour through the factory revealed a stack of new ‘safety’ tanks, that combine grey and fresh water storage in the one, compact unit, ready to be rolled out on new models, while a custom-built Terra Sportz was being fitted with an Enerdrive lithium battery system, by one of a number of full-time electricians.

A range-topping 23ft Pride Platinum with lounge slide-out was also moving down the production line, and despite price tags stretching to $125,000, Osorio said demand was increasing for Nova's biggest luxury slide-out models.

As for the future, buyers can expect a similar model line-up next year, with a few styling and equipment tweaks. Nova boss Robert Cataldo is heading to this month’s Caravan Salon in Dusseldorf, Germany,  so expect some fresh ideas from the world's biggest caravan show to make their way into a new Nova ‘show stopper’ set to be unveiled at next year's Melbourne Supershow in late-February.

“We try to do something bold every year and make a statement for the major shows, like the (bright red) La Dolce Vita caravan a couple of years ago… We even have customers now asking ‘What are you planning for next year’s show. We can’t wait!'”