Custom Mobile Production Trucks for Professional Broadcast Workflows

TV Pro Gear designs and builds broadcast TV trucks for organizations that need reliable, field-ready production capability in a fully integrated mobile environment. From live sports and concerts to broadcast television, corporate events, government programming, education, worship, and streaming, a professionally engineered broadcast truck gives your team the control, flexibility, and confidence to produce high-quality content from nearly any location.


A broadcast TV truck is more than a vehicle with equipment racks. It is a complete mobile control room designed around signal flow, operator efficiency, technical reliability, crew comfort, and real-world production demands. TV Pro Gear specializes in the design, engineering, and assembly of mobile video production systems for trucks, cargo vans, trailers, and Flypacks, giving clients a practical path to professional mobile production at the scale that fits their workflow. 

Expand Your Imagination

TV Pro Gear engineers work closely with Gerling engineers to create the CAD layout drawings for the vehicles. In addition, the companies’ technical staffs work hand-in-hand to design and specify HVAC, electrical distribution, storage bays, consoles, racks, wall, floor and ceiling treatments. Of course, during this process, the client has final approval.


A “Rack Ready” vehicle is one that has all of the HVAC, electrical distribution, equipment consoles and equipment racks installed. Once the “rack ready” vehicle is completed at Gerling & Associates factory in Sunbury, Ohio, it is moved to one of TV Pro Gear’s System Integration facilities in New York or Los Angeles.


Built for Live Production in the Field

Live production requires speed, precision, and dependable system performance. When your crew arrives on site, the truck must support fast setup, clean routing, stable monitoring, clear communications, and consistent output from the first camera check to the final program feed. TV Pro Gear broadcast TV trucks can be designed for a wide range of production environments, including:


Sports broadcasts, concerts and festivals, corporate conferences, broadcast television programming, government meetings, educational events, houses of worship, e-sports productions, live streaming and hybrid events, remote and outside broadcast productions.


Whether you need a compact mobile unit or a larger outside broadcast truck, TV Pro Gear can design a system that supports your camera count, signal format, crew size, production standards, and delivery requirements.



TV Pro Gear’s wiring technicians and engineers install all of the video, audio and transmission equipment. Only the highest quality wire and connectors are utilized. All wires get labels at both ends indicating source, destination and CAD reference number. Wires are dressed in and secured according to military and NASA specifications.



After the equipment is installed and wired, TV Pro Gear’s engineers perform System Configuration on such items as the switcher, router, intercom, replay and camera base stations. Next, TV Pro Gear Quality Assurance Engineers begin a lengthy testing procedure. Every input and output is repeatedly tested for continuity and signal quality. In addition, the QAE staff verifies that the “As Built” CAD drawings conform to reality. Finally, all equipment manuals are bound together along with a CD-ROM copy of the manuals.

Configured Around Your Production Requirements


Every broadcast truck should reflect the way your team actually produces content. TV Pro Gear builds custom mobile systems instead of forcing clients into a one-size-fits-all package. Vehicle size, equipment layout, rack configuration, power, HVAC, routing, switcher selection, replay, graphics, intercom, audio, monitoring, and streaming are all planned around the production workflow.

A custom broadcast truck may include:


Multi-camera production switching, camera control and shading, fiber camera systems, video routing and distribution, multi-view monitoring, professional audio mixing, intercom and IFB communications, instant replay and slow motion, graphics and title generation, recording and archiving, streaming encoders, satellite uplink or transmission options, engineering workstations, producer, director and technical director positions, equipment storage and cable management, TV Pro Gear’s mobile broadcast solutions include video vans, trucks, and trailers, with custom platforms that can be engineered for different production scales and transmission needs. 

Professional Engineering from Chassis to Signal Flow


A reliable broadcast truck begins long before the first camera is connected. The vehicle, physical layout, electrical system, cooling, racks, consoles, operator spaces, and cable paths all affect long-term performance. TV Pro Gear works with experienced chassis and vehicle partners to create mobile production platforms that are practical, durable, and ready for continuous field use.


For larger Expando Class broadcast TV trucks, TV Pro Gear notes that its 40-foot bumper-to-bumper trucks include a 32-foot work area box that expands to 12.5 feet wide and is designed to support up to 16 cameras. TV Pro Gear also works with Gerling and Associates, a chassis manufacturer with more than 700 broadcast video production truck chassis delivered since 1986. 


That level of vehicle experience matters. Broadcast trucks operate in demanding environments, often under tight schedules and high production pressure. Proper design helps reduce downtime, simplify maintenance, and create a more comfortable workspace for production teams.


Integrated Systems, Clean Wiring, and Tested Performance

The difference between a professional mobile production truck and a basic equipment installation is integration. A truck must be engineered so that each system works together as a dependable whole. TV Pro Gear emphasizes detailed system integration, including installation of video, audio, and transmission equipment, labeled wiring, CAD documentation, configuration, and quality assurance testing. 


This approach supports long-term serviceability and operational confidence. Crews need to know where signals are going, how systems are routed, and how to troubleshoot quickly during a live production. Clean integration also helps protect the investment by making upgrades, repairs, and future expansion more manageable.

Scalable Truck Options for Different Production Levels

Not every production requires the same size mobile unit. A regional sports producer, national broadcaster, university media department, corporate production team, or city government channel may each need a different configuration. TV Pro Gear can support a range of vehicle sizes and production platforms, including compact vans, 24-foot OB video vans, larger Hi-Cube trucks, Expando trucks, and custom mobile systems.


TV Pro Gear’s 24-foot OB video vans are described as custom-built broadcast video production trucks for live events, with options that may include multiple cameras, recorders, production switchers, intercom, wireless microphones, audio mixing, routers, test equipment, replay, slow motion, and streaming encoders. 


For larger productions, an Expando truck can provide additional workspace, more equipment capacity, and a more complete mobile control room environment. The right choice depends on your production goals, travel requirements, crew size, parking and venue limitations, and long-term growth plans.


Designed for Crew Efficiency and On-Air Confidence

A broadcast truck must serve both the technical system and the people operating it. Directors, technical directors, engineers, replay operators, graphics operators, audio mixers, producers, and camera shaders all need clear access to the tools they use under pressure. Good ergonomic design can improve communication, reduce fatigue, and help teams work more effectively during long production days. TV Pro Gear broadcast TV trucks can be designed with:


Logical operator positions, clear sightlines to monitors, accessible engineering areas, organized racks and patching, purpose-built production consoles, reliable power distribution, proper HVAC and ventilation, practical storage for field gear, efficient cable access, professional fit and finish

 

The goal is simple: create a truck that performs reliably, supports the crew, and reflects the professional standard of your organization.


Why Choose TV Pro Gear for Broadcast TV Trucks

TV Pro Gear brings together system integration, production experience, and mobile broadcast engineering. The company designs and builds television stations, production facilities, video trucks, and Flypacks for clients across a wide range of markets, including major media, corporate, government, and broadcast organizations.  Clients choose TV Pro Gear for:


  • Custom broadcast truck design 
  • Mobile production engineering 
  • Practical live production knowledge 
  • Professional system integration 
  • Scalable equipment configurations 
  • Clean documentation and wiring 
  • Field-ready quality assurance 
  • Support for live broadcast and streaming workflows 


A broadcast truck is a major investment. TV Pro Gear helps clients turn that investment into a dependable production platform built for current needs and future growth.

FAQ's

  • What is a broadcast TV truck?

    A broadcast TV truck is a mobile production vehicle equipped with the tools needed to produce live or recorded video in the field. It typically includes switching, routing, monitoring, audio, intercom, replay, graphics, recording, and transmission systems.


  • What types of productions use broadcast TV trucks?

    Broadcast TV trucks are used for sports, concerts, live events, television programming, corporate conferences, government meetings, education, worship services, and streaming productions.


  • Can TV Pro Gear build a custom truck?

    Yes. TV Pro Gear designs and integrates custom broadcast trucks based on production needs, camera count, workflow, crew size, vehicle requirements, equipment preferences, and budget.


  • How many cameras can a broadcast truck support?

    Camera capacity depends on the truck design and equipment package. TV Pro Gear offers mobile production solutions ranging from compact systems to larger Expando trucks designed to support up to 16 cameras. 


  • What is the difference between an OB truck and a production van?

    An OB truck, or outside broadcast truck, is typically larger and built for more complex field production. A production van is more compact and may be ideal for smaller crews, faster deployments, or venues with limited space.


  • Can a broadcast truck include streaming capabilities?

    Yes. Broadcast TV trucks can be configured with encoders and signal management tools for live streaming, broadcast delivery, recording, and hybrid event workflows.


  • Can the truck be upgraded later?

    Yes. A properly engineered truck can be designed with expansion in mind, including future upgrades for cameras, routing, replay, audio, graphics, monitoring, and transmission systems.


Build a Broadcast TV Truck Designed for Your Workflow

TV Pro Gear can help you design and build a broadcast TV truck that gives your team a professional mobile control room wherever production takes you. From compact video vans to full-scale outside broadcast trucks, TV Pro Gear delivers custom mobile systems engineered for reliability, flexibility, and high-quality live production.


Contact us to discuss your production requirements and start planning a custom broadcast TV truck built for your team, your workflow, and your future.

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