New Home Paves Way for Growth for Sunshine Coast Caravan Manufacturer

Zone RV has moved into a new purpose-built $8 million facility in Coolum Business Park on the Sunshine Coast.

Zone RV has grown from a start-up in 2015 to employing more than 90 staff and bringing nearly $40 million to the Sunshine Coast economy.

Using innovative composite structures and cutting-edge clean technologies Zone RV believes they are setting a new benchmark in quality and innovation creating caravans that are lighter, stronger and safer than those made with traditional manufacturing methods.

Sunshine Coast Council Economic Development Portfolio Councillor Steve Robinson congratulated the company on its growth.

“Zone RV has taken the traditional caravanning experience and incorporated advanced technology from the marine and aeronautical industries to create a product with exceptional water, energy and insulation management,” Cr Robinson said.

“This expansion allows the business to gain greater efficiencies and capabilities so they can further innovate to meet the excellence and expectations demanded of the national market.”

“They are another outstanding award-winning local business sharing best practice, learnings, and skills. I look forward to seeing them expand further as their sales and production grow.”

Zone RV plays an important role on the Sunshine Coast. They are increasingly entrepreneurial and collaborate locally, while value-adding to the region through their links to advanced manufacturing, tourism and clean technologies, which is, of course, one of our seven High-Value Industries.

Zone RV directors Matt Johns and Dave Biggar started the small business with two employees.

“We had experience across marine, aeronautical and civil construction but developing a new benchmark in the high-tech caravan manufacturing industry was a leap of faith that led to light-weight, dust and watertight caravans with a stylish and luxurious finish,” Mr Johns said.

“Thanks to our early adopters, we have had exciting growth and consumers now expect smarter solutions as standard.

“Zone RV uses the respected third party products, including local and Queensland suppliers incorporating the highest quality and innovative suspension systems, lithium batteries, and battery management systems – injecting a further $10 million a year into the local South-East Queensland economy.

“We have outgrown three facilities and are excited to move into this 4500m2 purpose-built factory, showroom and service center that also has a 4000m2 hardstand.

“The new factory delivers us a purpose-built designed factory layout for highest efficiencies to take us well into the future and the showroom offers an unparalleled client experience,” he said.

Mr Johns said Zone RV was planning to expand internationally, diversify products and continue to innovate and thanked Council for supporting them to expand and prosper. 

“The Sunshine Coast a great place to grow our business and we are thankful for strong industry development support from council through networking, advice, information, and links to Government programs/supply chain assistance,” Mr. Johns said.

“We are lucky to be expanding in a region where the council creates the right environment to grow businesses and support residents to have a bright future.”

For more information about Zone RV and to find out about their open day go to