DHL has taken a significant step towards decarbonizing road freight with the deployment of an Extended Range Electric Vehicle (EREV) developed in collaboration with Scania. The hybrid electric truck was tested over 100 days between DHL parcel centers in Berlin and Hamburg, covering a distance of approximately 22,000 kilometers. The EREV operated primarily on battery power, demonstrating strong environmental and operational performance despite charging infrastructure limitations.
The vehicle’s specifications include a 10.5-meter length, 40-ton gross vehicle weight, 230 kW electric motor, and 416 kWh battery capacity. The EREV also features a 120 kW fuel-powered backup generator, which was used only 8.1% of the time, allowing the vehicle to run on electric-only operation for 91.9% of the distance covered.
The results of the pilot project were impressive, with the EREV saving nearly 16 metric tons of CO₂e compared to a similar diesel truck. The vehicle’s operational impact was also stable, with reliable scheduling and route certainty even with charging constraints. The EREV’s ability to run on grid-charged electricity sourced from renewables for over 90% of the kilometers driven brought its emissions profile close to that of a fully electric truck.
The EREV proved to be a strategic asset for DHL, offering operational flexibility and ensuring route certainty even under unpredictable charging conditions. The vehicle’s design features scalable software controls that can limit generator use and align with future policy mandates. However, the EREV currently lacks proper classification under EU and national emission standards, and DHL has called for policy reforms to recognize proportional emission reductions.
The pilot project showcases a transitional yet effective solution for low-emission logistics, bridging the gap between current infrastructure constraints and long-term electrification goals. DHL is ready to scale up deployment, pending regulatory clarity. The EREV presents a compelling model for other logistics providers seeking practical and immediate climate action while broader EV infrastructure continues to develop. With its infrastructure-agnostic nature and ability to reduce emissions, the EREV is a viable path to decarbonize heavy freight operations today.