FEV analysis: Range-extender trucks cut TCO by up to 33% vs diesel without charging expansion
A new FEV analysis finds range-extender hybrid trucks can lower total cost of ownership by up to 33 percent versus diesel, even without megawatt charging infrastructure.
- 33%
- approximately 14%
- around 280 kWh
- up to 82%
What Happened
FEV, an engineering partner for sustainable mobility, has published new analysis from an internal research program on the economics of electrified commercial vehicles. Based on a realistic European usage profile with overnight depot charging at industrial electricity prices of about 19 cents per kilowatt hour, the study finds that range-extender trucks (REEV/Hybrid BEV) can achieve a total cost of ownership (TCO) up to 33 percent lower than conventional diesel trucks, depending on the driving cycle. Even in the most unfavorable long-haul scenario, TCO is reduced by approximately 14 percent. The approach requires no expansion of megawatt charging infrastructure.
- around 560 kWh
- around 280 kWh
- around 240 kWh
The smaller battery of a REEV truck reduces vehicle cost and weight and increases payload, while the high share of electric driving keeps energy costs low, especially with night-time depot charging. With little dependence on public high-performance charging, REEV trucks can integrate into existing depot structures, increasing operational flexibility and lowering investment risk for fleet operators. Overall, the combination yields a TCO advantage of about 14 percent in long-haul use and up to 33 percent in short-distance use. The analysis also reports a reduction in global warming potential of up to 82 percent, depending on application profile and energy mix.
“Our analysis clearly shows that the range extender makes electric trucks immediately economically and ecologically viable – without waiting for the widespread expansion of high-performance charging infrastructure. This is precisely what is crucial in long-distance transport.”
FEV has already shown the decarbonization potential of Hybrid BEV and REEV concepts in passenger cars, but this analysis focuses on commercial vehicles and long-distance transport, where economic strengths are most evident. The engineering service provider is working on demonstrator vehicles to validate the results practically and, with customers and partners, turn them into marketable solutions. The company says the technology reduces investment risk and increases operational flexibility for fleet operators.
“Range extender-based Hybrid BEV trucks offer an immediately available, economically highly attractive solution for electrified long-distance transport. They combine high electric driving ranges with minimal infrastructure requirements – and deliver measurable added value precisely where cost decisions are particularly sensitive.”
Why this matters
The analysis suggests fleet operators can get electric lorries that are economically competitive today, without waiting for high-power charging networks to be built. A smaller battery cuts up-front cost and weight, and the worst-case long-haul route still saves about 14 percent in TCO while cutting global warming impact by up to 82 percent. That matters because long-distance trucking is highly cost-sensitive.
Terms in This Story
- TCO
- Total Cost of Ownership: the complete cost of owning and operating a vehicle over its lifetime, including purchase, fuel, maintenance, and other expenses.
- REEV
- Range-Extended Electric Vehicle: an electric vehicle with a small internal combustion engine or generator that charges the battery to extend driving range.
- BEV
- Battery Electric Vehicle: a vehicle powered entirely by electricity stored in a battery, with no internal combustion engine.
- Megawatt charging
- Ultra-fast charging technology that delivers power in the megawatt range, intended for heavy-duty electric vehicles to recharge quickly on long trips.
Summarised from the linked release; details can be imperfect — always verify against the original source.