TCO Analysis: How Converting Diesel Trucks to Electric Reduces Your Fleet Costs by 30%
Rising diesel prices and CO2 taxes are impacting your bottom line. A complete TCO analysis of the fleet by converting diesel transporters to electric shows potential savings of over 30% in operating costs. Find out how to future-proof your trusted Mercedes-Benz Sprinter while benefiting at the same time.
The topic briefly and concisely
Converting from diesel to electric drive reduces operating costs per kilometer by about 33% due to lower energy and maintenance costs.
Government funding programs such as KsNI can cover up to 80% of the conversion costs and significantly accelerate the amortization.
The D2E conversion protects your investments in expensive specialized setups and is an active contribution to the circular economy that conserves resources.
For fleet operators in Germany, the pressure to switch to emission-free drives is increasing. Legal regulations and rising operating costs for diesel vehicles require a strategic realignment. The HEERO D2E conversion (Diesel-to-Electric) offers a pragmatic and economically superior solution. Instead of purchasing expensive new vehicles and disposing of proven transporters with special bodies, our approach allows for the continued use of your existing vehicle base. This analysis shows how targeted electrification can significantly reduce the total cost of ownership (TCO) of your fleet and prepare you for the future.
Cost drivers in focus: Why diesel fleets need to act now
The economic framework conditions for the operation of diesel commercial vehicles are continuously tightening. From January 1, 2025, the CO2 price in Germany will rise to 55 euros per ton, which increases the diesel price by an additional 3 cents per liter. In total, the CO2 surcharge on diesel will thus sum up to over 17 cents per liter, significantly driving up operating costs.
At the same time, emissions-free commercial vehicles benefit from significant advantages. A crucial relief is the exemption from truck tolls, which applies to e-transports until the end of 2025 and noticeably reduces the cost per kilometer. This combination of rising charges for fossil fuels and direct savings for electric vehicles creates a strong incentive for a quick transition. For logistics companies and municipalities, analyzing the total costs (TCO) of the fleet through the conversion from diesel transporters to electric is therefore no longer an optional step, but an economic necessity. The strategic decision for electrification of the fleet secures competitiveness for the coming years.
These financial incentives are specifically designed to accelerate the transition and set the course for sustainable logistics.
The TCO truth: Retrofitting far outperforms buying new
A comprehensive analysis of the total cost of ownership (TCO) reveals that converting an existing diesel van to an electric drive is often the most economical solution. While the purchase price of a new electric van can be over 55,000 euros, conversion conserves the budget and especially your existing investments. Particularly for vehicles with expensive special constructions, as common in craft businesses or municipalities, the HEERO D2E conversion avoids a capital loss of tens of thousands of euros.
Operating costs are the decisive factor where electromobility plays to its strengths. A study shows that the operating costs per kilometer for an electric van in Germany are only 10 cents, compared to 15 cents for a diesel. This corresponds to a direct saving of 33%. Here is a detailed comparison of the key TCO factors:
Energy costs: The electricity costs for 100 km are approximately 6-8 euros, while diesel costs for the same distance can amount to up to 15 euros.
Maintenance costs: Electric drives have fewer wear parts. Maintenance costs are up to 40% lower, as oil changes, exhaust systems, and clutch maintenance are unnecessary.
Taxes & Fees: The vehicle tax on electric vehicles is waived for up to 10 years, and the toll exemption until the end of 2025 provides further savings.
Investment protection: Your expensive and individualized constructions remain fully intact and ready for use.
Residual value: By continuing to use the chassis, its value is preserved, while the battery can be considered as a separate component, making the residual value calculation more transparent.
The amortization calculation for electrification shows that the investment often pays off after just a few years. This factual situation makes conversion the first choice for forward-looking fleet managers.
Technological Advantage: The HEERO D2E Conversion Process in 10 Days
The conversion of a diesel van into a state-of-the-art electric vehicle at Heero is a standardized and efficient process that is completed in just 10 days. We focus on the proven base of the Mercedes-Benz Sprinter to ensure reliability and a high availability of spare parts. Our patented D2E conversion kit replaces the combustion engine and all associated components with a powerful electric drive.
The result is a vehicle that matches the performance of a new vehicle. With a peak output of up to 245 hp and a practical WLTP range of up to 425 kilometers, our converted Sprinters are well-equipped for demanding tasks in logistics and craftsmanship. The retention of the original chassis and body ensures that the payload and cargo volume remain virtually unchanged. A cost-efficient conversion to electric drive is thus possible without any compromises in functionality.
This technological approach enables companies to modernize their fleets quickly and without the long delivery times of new vehicles. This makes the transition to e-mobility predictable and smooth.
Government funding as a TCO lever: Save up to 80% of the additional costs
The federal government supports the transition to clean commercial vehicles with attractive funding programs that significantly reduce investment costs. A central instrument is the funding program "Climate-friendly Commercial Vehicles and Infrastructure" (KsNI). Under current calls for funding, companies and municipalities can receive reimbursement of up to 80% of the additional investment costs for electrification. Applications for this can be submitted, for example, until August 31, 2025.
These subsidies are a critical lever to positively influence the total costs (TCO) of the fleet by converting diesel vans to electric. They reduce the initial financial barrier and accelerate amortization. The following funding options are particularly relevant:
KsNI Program: Subsidizes the additional costs for the purchase or retrofitting of electric commercial vehicles and the necessary charging infrastructure.
Tax advantages: In addition to the exemption from vehicle tax, companies benefit from favorable regulations regarding the taxation of company cars for electric vehicles.
Regional programs: In addition to federal programs, some federal states, such as Baden-Württemberg, offer their own subsidies for the purchase of electric trucks and the development of charging infrastructure.
KfW Loans: The Reconstruction Loan Corporation (KfW) offers low-interest loans for the financing of electric fleets and charging points.
A thorough examination of the available funding is an essential part of any TCO analysis. We support you in finding the right programs for your project and sustainably reducing operating costs.
More than just costs: Ecological and operational advantages of e-mobility
The decision to retrofit goes far beyond mere cost savings. It is a clear commitment to circular economy and sustainability. Instead of scrapping a fully functional vehicle, you extend its lifecycle by many years. This approach conserves valuable resources, reduces waste, and lowers CO2 emissions that would occur from the production of a completely new vehicle by up to 60%.
Operationally, your drivers and your company benefit from additional advantages. The retrofitted e-vans are quiet and low in vibrations, which increases driving comfort and reduces noise pollution in urban areas. Furthermore, you ensure unrestricted access to all environmental and zero-emission zones that already exist or are planned in German and European cities. This guarantees you maximum flexibility and operational reliability for the coming years. A sustainably modernized fleet also enhances your company image and positions you as a responsible partner to customers and in the public eye.
The retrofit is thus a holistic solution that combines economic logic with ecological responsibility.
Conclusion: Making your fleet future-proof and increasing profitability
The comprehensive analysis of the Total Cost of Ownership (TCO) clearly demonstrates: The conversion of diesel vans to electric drive is the smartest strategic decision for many fleet operators. It reduces operating costs by up to 33%, protects valuable investments in special bodies, and optimally exploits government subsidies. With a range of up to 425 km and a quick conversion process of only 10 days, the Heero D2E solution offers a powerful and pragmatic alternative to expensive new purchases.
By following the principles of the circular economy, you act not only economically wisely, but also sustainably and with foresight. Heero is your innovative partner that supports you in transforming your fleet. Secure your competitive advantages now and actively contribute to climate protection. Request a personal consultation or book an everyday test at no cost to experience the performance of our E-vans for yourself.
More useful links
Consumer Center Federal Association offers a summary of a TCO study (Total Cost of Ownership).
VDE publishes an article in the VDE Dialog about the total costs (TCO) of electric trucks.
Wikipedia provides a comprehensive article on Total Cost of Ownership (TCO), a method for calculating overall operating costs.
FAQ
How long does the conversion of my diesel van take?
The entire D2E conversion process at Heero is highly standardized and takes only 10 days. This way, you can quickly reintegrate your vehicle into operational use.
Which vehicles can be converted?
Heero specializes in the conversion of Mercedes-Benz Sprinter models. This ensures the highest quality, reliability, and optimal integration of our patented electric drive train.
What happens to the payload and loading volume after the conversion?
Since the original chassis and body structure of the vehicle are retained, there are hardly any changes in loading volume and payload. Our engineers ensure the practical usability of your van is fully maintained.
Does Heero support in applying for subsidies?
Yes, we see ourselves as your partner in the entire transformation process. Our team advises you on current subsidy programs from the federal and state governments and assists you in the application process to ensure maximum financial relief for your fleet.
Can I test a converted electric van?
Absolutely. We are convinced of the performance and practical usability of our vehicles. Therefore, we offer potential customers a free daily test. Just book a test drive and experience the benefits for yourself.
How does the conversion affect the TCO?
The conversion significantly reduces the TCO. Lower expenses for energy, maintenance, taxes, and tolls lead to operating cost savings of over 30%. We would be happy to create an individual TCO analysis for your fleet during a personal consultation.
