Electrifying the sprinter chassis: Protecting special superstructures and reducing TCO by 30%
Is your Mercedes Sprinter with expensive custom construction facing the end due to diesel driving bans? Retrofitting to electric not only protects your investment of often over 50,000 euros but also ensures continued use for the next 10 years. Discover how you can continue to utilize your reliable chassis while significantly reducing operating costs.
The topic briefly and concisely
Protect your investment: Upgrade your Sprinter chassis with a specialty electrical conversion instead of replacing it with an expensive new purchase.
Reduce total operating costs (TCO) by up to 30% through lower energy and maintenance costs compared to a diesel or a new electric transporter.
Act in a future-proof and sustainable manner by conserving resources and avoiding CO₂ emissions through continued use in the sense of a circular economy.
For fleet operators of Mercedes Sprinter vehicles with custom and expensive builds, looming diesel driving bans and rising operating costs pose a massive challenge. Investing in a completely new e-transporter involves costs of over 70,000 euros and means the loss of the proven special build. Heero offers an innovative solution here: convert the Mercedes Sprinter chassis with custom build to electric and continue to use it. This approach, based on the principle of a circular economy, not only conserves valuable resources but also significantly reduces the total cost of ownership (TCO). Our patented D2E conversion (Diesel-to-Electric) transforms your existing vehicles into powerful, future-proof e-transporters with up to 425 km range in just 10 days.
The economic deadlock: High investments in special constructions provide protection
Many companies and municipalities have invested six-figure amounts in Mercedes Sprinter with special bodies – from refrigerated boxes to workshop fittings to aerial work platforms. The lifespan of such bodies often exceeds that of the base vehicle by more than 10 years. Purchasing a new e-transporter would destroy this investment and incur additional costs of 20,000 to 40,000 euros for a new, identical body. Therefore, continued use of the chassis and body is the most economically sensible approach. The certified conversion of Mercedes commercial vehicles by Heero completely avoids this capital loss. This approach ensures the amortization of your original investment over many more years.
HEERO D2E conversion: Technological leadership in 10 days
The conversion of a Mercedes Sprinter chassis to electric is a standardized and highly efficient process at HEERO. Within just 10 working days, the diesel powertrain is replaced by our powerful 245 HP electric drive. This process not only retains the chassis and body but also the full functionality of all auxiliary drives. Our solution is not a niche, but an established technology already used in many municipal fleets. We specifically focus on young used vehicles to maximize the principles of the circular economy. The process includes the following steps:
Analysis of the base vehicle and the body (1 day)
Removal of the complete diesel powertrain (2 days)
Installation of the pre-assembled HEERO electric drive module (3 days)
Integration of battery modules and the charging system (2 days)
Software calibration and system tests (1 day)
Technical acceptance and quality assurance (1 day)
The result is a vehicle that surpasses many new e-transporters in terms of performance and range. With this technological superiority, you position your fleet for the demands of the next decade.
TCO analysis: Retrofitting is up to 30% cheaper than buying new.
The total cost of ownership (TCO) is the crucial factor for the profitability of a fleet. A retrofit is clearly advantageous here. While the procurement costs for a new e-transporter are high, the costs for a Heero D2E retrofit are significantly lower. Studies show that e-commercial vehicles are often already cheaper to operate than diesel vehicles, with cost advantages of up to 0.15 euros per kilometer. Our customers save up to 30% of the TCO over a holding period of 8 years by retrofitting compared to buying a new comparable e-vehicle with a new design. Especially the lower maintenance and energy costs contribute to this savings. Additionally, the retrofit is eligible for funding, which further reduces the investment costs. A detailed analysis of fleet TCO quickly highlights the enormous savings potential.
Circular economy as a future model for your fleet
By retrofitting your Mercedes Sprinter chassis with a custom body to electric and continuing to use it, you are acting in the spirit of a future-oriented circular economy. Instead of prematurely scrapping a functioning vehicle and a valuable body, you extend their lifecycle by at least 10 years. This reduces the need for primary raw materials like steel and aluminum by over 70% compared to the production of a new vehicle. EU policy actively promotes this approach to reduce raw material dependencies and increase resource efficiency. Each retrofit avoids the CO₂ emissions that would occur during the production of a new transporter – often more than 10 tons of CO₂. This makes a measurable contribution to achieving your sustainability goals in your fleet and positions your company as a leader.
Practical examples: Value preservation for municipalities, logistics, and crafts
The advantages of retrofitting are evident in many industries that rely on Sprinter chassis with expensive superstructures. Continued use is not only an option here but a strategic necessity. Examples of vehicles we regularly retrofit include:
Municipal vehicles: Street sweepers, refuse collection vehicles, or transporters for parks departments with superstructures worth over 60,000 euros.
Logistics and delivery services: Box superstructures for furniture transport or refrigerated vehicles for food logistics.
Craft businesses: Workshop vehicles with complex shelving systems and expensive equipment.
Special vehicles: Sales vehicles, food trucks, or vehicles for disaster relief.
For these businesses, retrofitting means securing a central working resource. The alternative, buying new, is often associated with months of waiting time for the special superstructure.
Future security: A step ahead of legal requirements and driving bans
The regulatory framework for commercial vehicles is continuously tightening. Cities like Stuttgart, Munich, and Darmstadt have already introduced driving bans for Euro 5 standards and worse. More cities will follow, and a tightening of the limit values is foreseeable. Retrofitting to an emissions-free electric drive offers you 100% planning security and unrestricted access to all environmental zones. You make your fleet independent from future political decisions regarding diesel vehicles. This is not a reactive step, but a proactive strategic decision that guarantees the operational capability of your fleet for the next decade. The electrification of your fleet is the best choice for a secure future.
More useful links
The Wuppertal Institute deals in this PDF with research results or studies in the field of environment and sustainability, possibly in the context of transport or energy.
The VDE Dialog addresses in this article the total cost of ownership (TCO) of electric trucks.
Strategy& (PwC) discusses in this press release the breakthrough of electric trucks.
The Federal Office for Logistics and Mobility (BALM) informs on this page about the funding program Climate Protection and Innovations in Commercial Transport (KSNI).
The KfW describes on this page four funding options for sustainable mobility for companies.
The DIHK addresses on this page the promotion of the circular economy in vehicles.
The Federal Environment Agency informs on this page about environmental zones in Germany that were established to reduce fine dust pollution.
The Fraunhofer IML discusses on this page the topic of e-mobility.
The VDA addresses on this page the drive strategy for commercial vehicles.
FAQ
How long does the conversion of a Sprinter chassis take?
The entire conversion process at Heero is designed for maximum efficiency and usually takes only 10 working days from the delivery of the vehicle to the handover.
Does the payload of my vehicle remain after the conversion?
Yes, we place great emphasis on ensuring that the payload of your vehicle is preserved as much as possible. By using modern, lightweight components and an optimized arrangement of the batteries, we ensure that your converted Sprinter retains its transport capacities.
Can my special setup (e.g. refrigerated trailer, workshop equipment) continue to operate?
Absolutely. Our D2E conversion is designed to ensure full functionality of special setups and their auxiliary drives. Your vehicle can be used for its specific tasks exactly as before after the conversion.
What warranty does Heero offer on the conversion?
Heero offers a comprehensive warranty on the electric drivetrain and the installed components. You receive a warranty comparable to that of new vehicles, providing you with long-term security.
Is the conversion possible for all Mercedes Sprinter models?
We specialize in the common models of the Mercedes-Benz Sprinter. Contact us with the details of your vehicle, and we will promptly check the compatibility for a D2E conversion.
Does Heero also offer consulting on charging infrastructure?
Yes, we offer a comprehensive solution that also includes consultation on suitable charging infrastructure for your premises. We analyze your needs and recommend the most economical and powerful charging solution.
