China’s electric vehicle industry is expanding rapidly across the globe, but a shortage of specialized Roll-on/Roll-off (Ro-Ro) car carriers has created a major logistical challenge. To keep exports moving, Chinese automakers are turning to innovative shipping solutions that go beyond traditional methods. These new approaches are helping manufacturers like Leapmotor and BYD deliver vehicles to international markets despite capacity constraints.
Leapmotor’s Flat Rack Shipping Solution
Leapmotor, backed by Stellantis, has adopted a ‘Flat Rack’ transport method developed by COSCO Shipping Specialised Carriers. Instead of relying solely on Ro-Ro vessels, Leapmotor secures its vehicles onto metal racks, which are then loaded onto conventional cargo ships. This approach has already enabled the company to ship over 1,800 vehicles to Brazil, where Stellantis’s established logistics network handles final delivery.
Alternative Shipping Methods Gain Traction
With Ro-Ro capacity stretched thin, Chinese automakers are increasingly using containerized shipping and specialized frames. A standard 40-foot container can typically hold 2 to 4 vehicles, offering a flexible and cost-effective alternative. COSCO Shipping Specialised Carriers has also transformed its 62,000-dwt multipurpose pulp carriers by equipping them with proprietary 48-foot foldable ‘Flat Rack’ frames. These allow vehicles to be driven on, secured, and stacked up to 8 layers high inside the cargo holds, enabling each ship to carry over 1,000 cars per voyage.
For commercial vehicles, COSCO has developed the V-Rack, an ultra-wide foldable frame designed to accommodate larger models. These innovations are helping Chinese manufacturers maintain export momentum despite the ongoing shortage of specialized car carriers.
BYD’s Investment in Dedicated Car Carriers
BYD, recognized as the world’s leading manufacturer of new energy vehicles, has responded to the shipping crunch by commissioning the construction of several dedicated car carriers. These vessels have already begun entering service, further strengthening BYD’s ability to deliver vehicles to overseas markets.
Competitor Comparison
While Leapmotor and BYD are leading the way with innovative shipping strategies, other global automakers are also seeking solutions to the Ro-Ro shortage. European and American manufacturers have traditionally relied on established Ro-Ro networks, but the current capacity crunch is prompting many to explore containerized shipping and alternative logistics partnerships. Chinese brands are notable for their rapid adaptation and willingness to invest in new shipping infrastructure.
Historical Context
China’s retail sales, including automotive exports, have shown a recovery trend since 2022, with a year-on-year increase of 4.8%. This growth has intensified the need for efficient vehicle shipping solutions as more Chinese-made EVs reach global markets.
Why this matters
The shortage of specialized car carriers could have slowed China’s EV export boom, but the adoption of alternative shipping methods is keeping supply chains moving. These innovations ensure that Chinese automakers can meet international demand and maintain their competitive edge in global markets.
What this means for buyers
For international buyers, these new shipping solutions mean continued access to Chinese EVs without major delays. As automakers invest in dedicated logistics and flexible shipping options, customers can expect more reliable delivery times and a steady flow of new models in overseas markets.
Key Specs
- Leapmotor vehicles shipped to Brazil: Over 1,800
- COSCO Shipping Specialised Carriers fleet: 62,000-dwt multipurpose pulp carriers
- Flat Rack frame length: 48 feet (~14.6 meters)
- Cars per voyage (Flat Rack system): Over 1,000
- Stacking capacity: Up to 8 layers high
- Vehicles per 40-foot container: 2 to 4
- Year-on-year retail sales growth: 4.8%
Source
Images sourced from: carnewschina.com, leapmotor.net
