Retrofitting existing vehicles: Secure high residual value & switch to electric drive
Up to 425 kilometers of range after a diesel-to-electric upgrade – without the cost of a new vehicle. The time for an upgrade is now, as the current funding round with 80% subsidy ends on August 31, 2025.
The topic briefly and concisely
Converting existing vehicles to electric drive ensures high residual values and reduces total operating costs (TCO) by 80% through subsidies.
The deadline for applying for the attractive KsNI funding from the BMDV ends on August 31, 2025, which requires quick action.
By continuing to use the vehicle chassis in the spirit of the circular economy, valuable resources are preserved and CO₂ emissions are reduced.
Rising operating costs, strict CO₂ regulations, and impending driving bans are putting pressure on fleet operators. Especially for vehicles with expensive special superstructures, a new purchase is often not economically viable. The solution lies in retrofitting your existing vehicle with a high residual value to a future-proof electric drive. This retrofit, known as Diesel-to-Electric (DTE), not only protects your budget but also signifies a clear commitment to the circular economy. With government subsidies of up to 80% for the retrofit and 40% for the charging infrastructure, the switch becomes manageable and profitable. This article shows you how to set the course for an emissions-free and economical future.
Why retrofitting is the most economically viable decision now
Given that over 6,600 climate-friendly trucks have already been funded, many fleets face a strategic decision. Legal frameworks such as the Clean Vehicles Directive (CVD) are forcing primarily municipalities and public enterprises to convert their fleets. By 2025, 38.5 percent of newly procured light commercial vehicles must be low-emission. At the same time, unpredictable diesel prices and new CO₂ taxes make cost planning a challenge. Retrofitting existing vehicles is the pragmatic answer here. It follows the principle of sustainable circular economy, preserving valuable vehicle superstructures and conserving resources. Studies show that significant CO₂ emissions can be saved by using secondary raw materials. Instead of investing in an expensive new purchase, which often has long delivery times, you specifically modernize the drive technology. This approach not only secures the value of your special vehicles but also prepares your fleet for the next ten years. Therefore, the conversion is not just a pure cost factor, but an investment in long-term competitiveness.
In 4 steps to funding: Your pragmatic action plan
The path to the subsidized electrification of your fleet is straightforward and can be implemented quickly with a clear strategy. Here is your checklist for a successful diesel-to-electric conversion:
Inventory and Needs Analysis: Together we will assess the condition of your vehicles and analyze the exact requirement profile. Daily mileage, load, and area of application determine the optimal technical design for a range of up to 425 kilometers.
Funding Check: Time is of the essence, as applications for the current funding round must be submitted by August 31, 2025. We identify the suitable funds from the KsNI guidelines of the BMDV, which cover up to 80% of the conversion costs.
Cost-Benefit Analysis (TCO): We create a transparent comparison of the Total Cost of Ownership (TCO), i.e., the overall operating costs. This analysis shows how the higher initial investments can quickly pay off through savings in energy, maintenance, taxes, and tolls.
Implementation and Charging Planning: After the funding commitment, we plan the conversion, which often takes just a few days. In parallel, we design the appropriate charging infrastructure, which is also subsidized by up to 40% and optimizes your operational processes.
A logistics company from Stuttgart was able to maintain its Sprinter fleet with refrigerated bodies and reduce the total costs per vehicle by 15%. Planning and implementing the next steps is crucial for success.
Funding pots and deadlines 2025: How to maximize your grants
The current funding landscape offers a unique opportunity to advance electrification cost-effectively. The central instrument is the guideline for funding commercial vehicles with alternative, climate-friendly drives (KsNI) from the Federal Ministry for Digital and Transport (BMDV). The final deadline for applications is August 31, 2025. The high demand in recent funding calls demonstrates the urgency. The funding rates are clearly defined:
80% of the additional investment costs for the acquisition of an electric vehicle or the DTE conversion of an existing vehicle.
40% of the costs for the establishment of the necessary non-public charging infrastructure on your premises.
Grants for feasibility studies to analyze the electrification potential in your fleet.
This funding is crucial to meet the requirements of the Clean Vehicles Directive without breaking the budget. It provides planning certainty and makes the conversion an immediately profitable decision. A precise understanding of the financial framework conditions is the first step towards technical implementation.
Cost comparison: How the DTE retrofit reduces the TCO of your fleet
The diesel-to-electric conversion (DTE) is more than just a simple technology switch; it is a strategic lever to reduce your total cost of ownership (TCO). While the acquisition costs for electric vehicles are higher, the investment pays off through significantly lower operating costs. A TCO analysis shows that electric trucks already achieve TCO parity with diesel counterparts in many segments today. The savings result from several factors:
Energy costs: The electricity costs per kilometer are significantly lower and more stable than those for diesel.
Maintenance and repair: Electric drives have fewer wear parts, which can reduce maintenance costs by up to 50%.
Taxes and fees: Electric vehicles benefit from a ten-year exemption from vehicle tax and lower CO₂-based toll fees.
Residual value: By the conversion, you protect the value of your expensive special structures, which would be lost if the diesel vehicle were sold.
Especially in urban delivery traffic with frequent stop-and-go operation, electric drives fully exploit their efficiency advantages. These financial benefits, combined with the high performance of the vehicles, make the conversion a wise business decision.
Range and charging power: The technical facts of the HEERO solutions
The practicality of an electric utility vehicle stands and falls with range and charging performance. Our conversion solutions are designed for demanding commercial use and are based on over ten years of experience. We only use new, certified components to ensure maximum lifespan and performance. Here are the specifications of our most common models:
Heero DTE-Sprinter: Up to 425 km range, ideal for regional distribution and crafts.
Heero E-Transporter: Up to 500 km range for demanding delivery traffic.
Heero Low-Floor Buses: Up to 300 km range for reliable public transport.
Battery capacity: Standard 110 kWh gross (96 kWh net), ensuring high range even when fully loaded.
Fast charging power (DC): With up to 135 kW (up to 165 kW for buses), the battery is recharged to 80% in about 40 minutes.
These performance data ensure that your converted vehicles can handle daily routes without compromise. The combination of high range and fast charging ensures maximum availability and efficiency in daily operations. This clears the way for the last, decisive step.
Your next step: Start the free funding analysis
Don't wait until the funding deadlines pass and regulatory pressure limits your options. Act now to secure the maximum support for retrofitting your fleet. Start your funding analysis: Answer three brief questions about your fleet, and you'll receive a tailored grant roadmap from us. We will guide you through the entire process so you can use the 80% funding on time. Secure your free and non-binding analysis now.
Get your free analysis
free · non-binding · on time
More useful links
Statista provides comprehensive statistics and information on electric mobility.
The Federal Office for Logistics and Mobility (BALM) provides detailed information on the funding program for climate protection and sustainability in the domestic sector (KSNI).
The German Automobile Trust (DAT) supplies important information regarding the residual value of electric cars.
The VDA (Association of the Automotive Industry) addresses the topic of circular economy in the context of climate, environment, and sustainability.
The Fraunhofer UMSICHT describes the EKODA project, which is focused on the development of circular strategies for electric mobility.
The Federal Environment Agency confirms the climate benefits of electric cars in a press release.
The Federal Ministry for Digital and Transport (BMDV) provides an overview of electric mobility in Germany.
DEKRA offers information on retrofitting trucks for electric drive.
FAQ
How long does a Diesel-to-Electric conversion take?
The pure conversion time in our factory usually takes only a few working days. Including all preparations and follow-up work, you can expect a total duration of about two to three weeks until your vehicle is fully operational again.
What guarantees are there for the conversion and the battery?
Heero offers comprehensive guarantees on all newly installed components. You will receive a multi-year warranty on the electric drive train and the high-voltage battery, which is based on the standards of vehicle manufacturers and provides you with long-term security.
Do I have to apply for funding myself?
No, you don't have to. We offer comprehensive funding advice and actively support you in the application process to make the process as simple and efficient as possible and to secure the maximum funding amount.
What happens to the old diesel engine?
In the spirit of the circular economy, the removed diesel engines and components are professionally reconditioned and supplied to the spare parts market. This prolongs the lifecycle of the parts and avoids waste.
Is the conversion possible for every vehicle?
We specialize in light commercial vehicles, particularly those based on the Mercedes-Benz Sprinter, as well as buses. For these models, we offer standardized and certified conversion solutions. Contact us for an individual assessment of your vehicle.
Does the payload of my vehicle change due to the conversion?
The weight of the electric drive and the battery is partially compensated by removing the heavy diesel engine, transmission, and full tank. Depending on the configuration, there may be a slight change in payload, which we calculate precisely in advance and coordinate with you.
