Retrofit municipal utility vehicles to zero emissions: Economical and future-proof
Rising cost pressure and stricter environmental regulations are forcing municipal fleets to take action. Converting existing diesel vehicles to a high-performance electric drive is a pragmatic solution. It not only ensures compliance with regulations but also conserves budgets and valuable resources.
The topic briefly and concisely
The conversion of existing municipal commercial vehicles protects investments in expensive specialized equipment and avoids their premature depreciation.
Thanks to funding programs and lower operating and maintenance costs, the total cost of ownership (TCO) of a retrofitted vehicle decreases by up to 40% compared to diesel.
The HEERO D2E retrofit ensures compliance with the Clean Vehicles Directive and access to future zero-emission zones in city centers.
Cities and municipalities in Germany face a double challenge: The EU Directive for Clean Vehicles mandates binding quotas for zero-emission new acquisitions, while at the same time more and more city centers are establishing zero-emission zones. For municipal fleets, which often rely on expensive specialty vehicles, this means an enormous investment pressure. The purchase of a complete electric vehicle is not only costly but also leads to the premature write-off of valuable installations. Heero offers a technologically leading and economically superior alternative with the patented D2E conversion (Diesel-to-Electric) to make municipal utility vehicles fit for the transition to zero emissions in compliance with urban regulations.
Act in compliance with the law: The Clean Vehicles Directive as a driver
Key Insights
Investment Protection: The conversion retains expensive special constructions and avoids an early depreciation of up to 80% of the vehicle's value.
Cost Effectiveness: Through the D2E conversion, the total cost of ownership (TCO) can be reduced by up to 40% compared to diesel.
Future Security: Converted vehicles meet the criteria for zero-emission zones and the EU's Clean Vehicles Directive.
Sustainability: The principle of circular economy avoids CO2 emissions that occur during the production of a new vehicle.
The EU directive for clean vehicles, implemented in Germany through the Clean Vehicles Procurement Act (SaubFahrzeugBeschG), is not a paper tiger. It has been mandating public buyers since August 2021 to adhere to binding minimum quotas for low-emission and zero-emission vehicles in procurement. For light commercial vehicles, the quota is 38.5%, with a significant portion needing to be completely emission-free by 2026.
This regulation directly affects the core of municipal services, from waste disposal to green space maintenance. Cities like Hamburg and Stuttgart are already planning driving bans that will significantly restrict the use of diesel vehicles in urban areas. The transition is thus no longer an option, but a necessity to ensure public services in the future. The challenge is to make this change without overwhelming municipal budgets.
The dilemma with special setups: buying new is often not a solution.
A typical municipal vehicle, such as a sweeping machine or a flatbed truck with a crane based on a Sprinter, has a lifespan of 10 to 15 years. The expensive special superstructure often accounts for more than 50% of the total value. Purchasing a new electric equivalent would mean prematurely scrapping this still fully functional and valuable technology.
This destruction of capital is economically and ecologically nonsensical. The investment in a new E-transporter with a special superstructure can quickly exceed €150,000, while the existing structure would still be usable for many years. This is precisely where the strategic conversion comes in, bridging the gap between regulatory obligation and economic sense.
The HEERO D2E conversion: Protect investments and increase performance
Instead of decommissioning a proven vehicle, Heero exchanges the diesel powertrain for a state-of-the-art electric system. This process, known as D2E conversion, is Heero's core competency and is based on the principle of the circular economy. The entire conversion process is designed for maximum efficiency and quality.
The procedure is clearly defined and takes only about 10 working days:
Analysis of the base vehicle and the requirement profile.
Removal of the complete diesel powertrain including the tank and exhaust system.
Installation of the pre-assembled Heero E-drive system with motor, battery, and power electronics.
Integration into the existing vehicle electronics of the Mercedes-Benz Sprinter.
Comprehensive quality control and test drives before delivery.
The result is a vehicle that not only meets regulations for the next 10 to 15 years but also retains or even exceeds its original performance. This ensures future viability for low-emission zones without needing to tie up new capital.
Technical data that convinces: Focus on range and payload
The concerns about e-commercial vehicles often relate to range and practicality. The Heero technology disproves these reservations with impressive performance data, specifically tailored to the requirements of municipalities, logistics, and crafts. A retrofitted Sprinter offers a practical solution without compromises.
The technical specifications speak for themselves:
Range: Up to 425 km according to WLTP City, which far exceeds the typical daily distances of 80-120 km in municipal use.
Performance: A peak output of 150 kW ensures dynamic acceleration and ample power reserves.
Payload: The payload remains almost identical to the original diesel vehicle, so there are no restrictions on loading.
Charging Time: At a DC fast-charging station, the battery is charged from 20% to 80% in just about 60 minutes.
These figures prove that the retrofit of municipal commercial vehicles to zero emissions is not only a regulatory exercise but represents a technological upgrade. A practical example from Bergisch Gladbach shows the successful implementation in everyday waste management.
TCO analysis: How retrofitting can reduce operating costs by up to 40%
The decision to retrofit is primarily an economic one. A full cost accounting (Total Cost of Ownership, TCO) shows that the Heero D2E solution is superior to a new diesel or electric vehicle. The savings result from several factors that accumulate over the years.
Lower operating costs are a central advantage. Energy costs per 100 km are significantly lower for an electric drive than for diesel. In addition, expensive maintenance items such as oil changes, exhaust system repairs, or the replacement of wear parts on the combustion engine are eliminated. A saving of around 50 percent on maintenance costs is realistic.
Additionally, municipalities benefit from funding programs that explicitly support the retrofitting of commercial vehicles and can cover up to 80% of the costs. Combined with the exemption from vehicle tax for electric vehicles, the investment in retrofitting pays off significantly faster than a new purchase. The use of existing stock is therefore the smartest choice.
Conclusion: Your advantage with HEERO – Partnership for a clean and economical future
The conversion of municipal fleets to emission-free drives is inevitable. HEERO offers a solution with the D2E conversion that intelligently combines ecology and economy. You not only ensure compliance with current and future city regulations but also protect investments made in expensive special structures and sustainably reduce your operating costs.
By continuing to use existing vehicles in the spirit of the circular economy, you make an active contribution to resource conservation. HEERO is more than just a supplier; we are your innovative partner who accompanies you from analysis through funding to implementation. Set the course now for a future-proof fleet.
Experience the advantages for yourself. Request your personal consultation now or book a daily test for free.
More useful links
The Federal Ministry for Digital and Transport offers a fact sheet on electromobility in municipalities.
The German Cities and Municipalities Association provides a guide to charging infrastructure in municipalities.
The Wuppertal Institute publishes a study on the topic of electromobility.
e-mobil BW offers application examples for the electrification of fleets.
The Federal Environment Agency provides comprehensive information on climate protection in transport.
An analysis of the environmental balance of motor vehicles is available at the Federal Environment Agency.
The National Platform Future of Mobility (NPM) offers a workshop report on the topic of commercial vehicles.
FAQ
Why is converting existing vehicles more sustainable than buying new ones?
The conversion is a prime example of the circular economy. It avoids the CO2 emissions and the enormous resource consumption that arise from the production of an entirely new vehicle chassis and body. In this way, valuable resources are conserved, and the lifespan of proven technology is extended.
Will the payload of my special vehicle remain after the conversion?
Yes, the payload of the converted vehicle remains nearly identical to that of the original diesel vehicle. Our electric drive system is designed to compensate for the weight of the removed diesel engine, transmission, and tank.
Does Heero also offer support for applying for funding?
Absolutely. We see ourselves as a holistic partner for your fleet electrification. Our team provides comprehensive advice on the available federal and state funding programs and actively supports you in the application process to secure the maximum funding for your project.
What warranty is there on the conversion and the battery?
Heero grants a comprehensive warranty on all installed components of the electric drivetrain. You receive a multi-year warranty on the high-voltage battery and all other central system parts, ensuring you long-term security and reliability.
Can every Sprinter model be converted?
Our D2E system is validated for a wide range of Mercedes-Benz Sprinter models, especially those with special bodies. For an accurate examination of the compatibility of your specific vehicle or fleet, please contact our expert team for a free analysis.
What happens to the removed diesel engine?
In the interest of sustainability and resource conservation, we ensure the proper recycling of the removed components. The engines and transmissions, depending on their condition, are refurbished and supplied to the spare parts market or handed over to certified recycling.
