Protect the value of your special structures: The conversion of the base vehicle as a strategic advantage.
Protect the value of your special structures: The conversion of the base vehicle as a strategic advantage.
Your custom-built vehicle is worth thousands of euros, but is the diesel base vehicle becoming a burden? A diesel-to-electric conversion secures your investment and makes your fleet future-proof.
The topic briefly and concisely
Protect the value of your expensive special setups by retrofitting the base vehicle from diesel to electric, instead of investing in new equipment.
The state KsNI subsidy funded the conversion with up to 80% of the additional costs and included the charging infrastructure; it ran until 2024 and has been discontinued.
A retrofit reduces the Total Cost of Ownership (TCO) through significant savings in energy, maintenance, and taxes, and is an active contribution to the circular economy.
Companies and municipalities face a dual challenge: rising operating costs and strict environmental regulations are putting a strain on fleets. Especially for vehicles with expensive custom bodies, such as refrigerated boxes or workshop fittings, the question arises of how to protect the value of these investments when the diesel base vehicle reaches its limits. The solution lies not in expensive new purchases, but in strategic conversion. This article shows you how, by electrifying your existing base vehicle, you can not only protect the value of your expensive custom bodies, but also realistically assess the funding situation and significantly reduce your Total Cost of Ownership. The federal KsNI funding program ran until 2024; no new calls for funding are planned.
Growing hurdles for diesel fleets with special superstructures
Pressure on fleet operators is growing daily. Diesel prices have shown high volatility over the past 24 months, complicating budget planning. At the same time, the EU is tightening requirements for public procurement with the Clean Vehicles Directive (CVD). By the end of 2025, 45% of newly procured buses must be "clean", and from 2026, this quota rises to 65%. For many companies whose expensive special bodies are mounted on diesel chassis, this represents a looming loss of value. Their investment of often more than 50,000 euros in an individual body is tied to a base vehicle that could soon be uneconomical or even impossible to use. This situation requires a pragmatic, value-preserving solution that goes beyond a simple new purchase. The electrification of the existing fleet is the direct way to overcome these challenges.
Your 4-point action plan for securing the value of your structures
To protect the value of your special superstructures, a structured approach is required. Instead of waiting for rising costs and driving bans, you can maintain control with a clear strategy. This 4-point plan serves as a pragmatic checklist for your decision.
Carry out inventory analysis: Identify all vehicles with high-quality superstructures whose leasing expires within the next three years or which possess a high residual value.
Check economic viability (TCO): Calculate the Total Cost of Ownership (TCO) for continued operation with diesel compared to conversion. Take fuel, maintenance, taxes, and subsidies into account.
Categorize deadlines and subsidies: The KsNI subsidy ran until 2024, new funding calls are not planned. Early planning remains crucial in order to correctly evaluate the previous 80% subsidy.
Evaluate certified conversion partner: Choose a partner who not only masters the technology, but also maintains the vehicle manufacturer's warranty and has proven experience with your vehicle model.
The implementation of this plan begins with a detailed analysis of the financial framework conditions, in particular the available subsidy pools.
Funding pools in review: 80% grant for the conversion
The Federal Government has heavily supported the transition to clean drivetrains. Through the guideline "Climate-friendly Commercial Vehicles and Infrastructure" (KsNI) of the Federal Ministry for Digital and Transport (BMDV), significant grants were possible. The funding rate was up to 80% of the additional investment expenses for converting a vehicle to electric drive. This means that the majority of the additional costs compared to a diesel equivalent were borne by the state. In addition, the acquisition of the necessary charging infrastructure was subsidized with 40% of the expenses. The crucial factor is the situation today: The KsNI funding ran until 2024, and no new funding calls are planned. Given this situation, the conversion pays for itself primarily through operating costs. A professional conversion partner can support you with the application process. The next step is to understand the long-term cost advantages.
TCO Analysis: Why Retrofitting Often Outperforms Buying New
The Total Cost of Ownership (TCO) is the decisive key figure for the profitability of a commercial vehicle. It includes far more than just the purchase price. A conversion offers clear advantages here. While the initial investment was heavily reduced by the 80% funding running until 2024, operating costs are falling drastically. Electricity costs per 100 kilometers are up to 70% lower than diesel costs. In addition, items such as the truck toll, vehicle tax, and costly maintenance of the combustion engine (e.g. oil changes, exhaust system) are eliminated. The decisive advantage, however, is that you continue to use 100% of your expensive and proven special body. A new purchase would not only mean the full price for a new electric vehicle, but also the costs for a completely new body. A conversion solution therefore protects your capital twice over. Learn more about the Total Cost of Ownership and how it is calculated. These financial advantages are underpinned by impressive technical performance data.
Performance without compromise: Range and charging power after the upgrade.
Concerns about a lack of range or performance are unfounded with modern electric retrofits. HEERO solutions are designed for demanding commercial use and utilize a standardized battery with 110 kWh gross or 96 kWh net capacity. This enables practical ranges for almost every application.
HEERO DTE-Sprinter: A range of up to 425 km ensures the reliable handling of regional routes.
HEERO eTransporter: With a range of up to 500 km, even longer distances are feasible without any problems.
HEERO ePritschenwagen: A range of up to 400 km offers flexibility for trade and municipalities.
HEERO Bus-Lösungen: The Tourer achieves up to 400 km, while the low-floor buses reach up to 300 km in city traffic.
The DC fast charging power of up to 135 kW (or 165 kW for the medium low-floor bus) ensures minimal downtime. In around 40 minutes, the battery is recharged to 80%. These performance data prove that a professional retrofit does not mean compromising on practicality. Rather, it combines economic advantages with emission benefits.
Circular economy in practice: Renovation instead of new purchase as a sustainability strategy
The decision to retrofit is more than just an economic measure; it is an active contribution to the circular economy. Instead of scrapping a fully functional vehicle including its body (linear "take-make-waste" model), you significantly extend its life cycle. By continuing to use the chassis and the entire body, a substantial share of the CO₂ emissions that would occur during the production of a new vehicle is saved. This principle of "remanufacturing" conserves valuable resources such as steel, aluminum, and plastics. In doing so, you not only act with an eye on emissions but also strengthen your image as a sustainable company. The electrification of your existing fleet is therefore the smartest way to combine economic rationality and emission reduction. Start your analysis now to set the course for a future-proof fleet.
More useful links
The Nationale Leitstelle Ladeinfrastruktur provides information on commercial vehicles, particularly in the context of logistics and transport.
The Bundesministerium für Digitales und Verkehr (BMDV) provides comprehensive information on climate protection in transport, with a specific focus on commercial vehicles with alternative drivetrains.
The Bundesministerium für Umwelt, Naturschutz, nukleare Sicherheit und Verbraucherschutz (BMUV) provides information on the circular economy and the management of end-of-life vehicles as a waste stream.
The Verband der Automobilindustrie (VDA) offers a detailed PDF document on the circular economy in the automotive sector.
Wikipedia offers a comprehensive article on electric vehicles, highlighting the basics, technology, and history.
The IHK München provides information on the diesel driving ban in Munich and its relevance for commercial traffic.
The Umweltbundesamt provides information on low emission zones in Germany and their connection to particulate matter.
The Deutsche Energie-Agentur (dena) examines the expansion of charging infrastructure for electric trucks, including relevant challenges and potential solutions.
