DHL and Scania are testing electric trucks with fuel-powered range extender

Key Highlights:

• Scania and DHL developed an electric truck with a fuel-powered generator to extend range.
• The truck has a 416 kWh battery, a 120 kW generator, and a range of 650–800 km.
• It will be tested for parcel transport between Berlin and Hamburg.
• Smart software minimizes generator use, reducing CO2 emissions by over 80%.
• DHL and Scania see it as a bridge to full electrification while infrastructure improves.

Scania and DHL Group have developed an electric truck with a fuel-powered generator. This allows the shift to battery-electric transport without waiting for a full charging network. Fully electric vehicles are the best solution for sustainable transport, and the transition needs to speed up. 

However, challenges like a lack of charging stations, high costs for extra charging capacity during peak seasons, and electricity price fluctuations create difficulties. Scania and DHL’s Extended Range Electric Vehicle (EREV) may solve these problems. It allows DHL to run 80–90% of its operations on renewable electricity while addressing charging limitations.

The new e-truck will be used by Post & Parcel Germany in February for parcel transport between Berlin and Hamburg. This test will check its performance in daily operations before more vehicles are added to DHL’s fleet.

Scania and DHL’s Extended Range Electric Vehicle 

The EREV is a 10.5-meter-long truck with a maximum weight of 40 metric tons. It is driven by a 230kW electric engine (295 kW peak). A 416 kWh battery and a 120 kW gasoline-powered generator supply energy. Because of the onboard generator, which is initially powered by petrol and later by diesel fuel/HVO, the truck's range is extended to 800 kilometres.

The fuel-powered generator replaces one of the battery packs, which is not needed for most transport routes. This reduces battery-only range but provides backup energy when required. The truck is expected to have a range of 650 to 800 kilometers, depending on test results, and can be refueled at regular petrol stations if needed. In comparison, Scania’s latest fully electric trucks have a range of 550 kilometers with the same maximum weight.

EREVs can be outfitted with software that restricts the use of the fuel-powered generator, allowing CO2 emissions to be minimized and limited to a set amount. Its maximum speed is 89 km/h, with a cargo capacity of about 1000 parcels (the volume of a swap body). The vehicle can also tow a trailer with an additional swap body. The vehicle is to be deployed for ‘main carriage’ transit between the cities of Berlin and Hamburg.

Leadership Insights

DHL Group CEO Tobias Meyer stated that it will take time for renewable electricity, the grid, and charging infrastructure to fully support battery-electric trucks, especially for a large-scale network like DHL’s in Germany. 

Instead of waiting, DHL and Scania are working on a practical solution to make logistics more sustainable and cut CO2 emissions by over 80%. He called the new electric vehicle a smart and effective way to reduce emissions in freight transport immediately. Meyer also emphasized that such reductions should be considered in road toll pricing and the EU fleet emission scheme, highlighting the project as a strong example of innovation in tackling climate change.

Scania CEO Christian Levin said that while the future of transport is electric, progress should not be delayed by waiting for perfect solutions. The vehicle developed with DHL is an interim solution that helps scale up low-emission heavy transport before a fully electric system is in place. 

He emphasized that a successful climate transition requires policymakers to support such solutions while increasing investments in public infrastructure and other necessary developments.

Also Read: Scania India Opens Advanced Training Centre in Chandrapur

CMV360 Says

Scania and DHL’s approach are practical for accelerating the shift to electric trucks. Instead of waiting for perfect infrastructure, they are offering a real-world solution that works within current limitations.