EV Trucks: The road to Sustainable Logistics

As major trucking companies decarbonize their fleets, they are currently often prioritizing lower-carbon fuels such as natural gas and biofuels over zero-emission trucks. Adopting these fuels marks a positive step toward sustainable commercial mobility but represents only an intermediate step toward zero-emission mobility in the commercial sector. Meanwhile, true zero- emission mobility in the form of electric or hydrogen-based trucking appears to be stuck in traffic as massive challenges delay adoption. The shift to zero-emission trucks requires more than simply changing power engines; it will disrupt the entire ecosystem. OEMs are heavily investing in the development, production, and sales of new powertrains along with greater digital integration. A major infrastructure investment costing billions is on the horizon, and utility companies are preparing for a surge in demand on their power grids. Beyond these supply-side challenges, fleet operators remain cautious about transitioning due to financial constraints, complex business cases, and operational obstacles.

OEMs and suppliers are facing significant challenges. They must develop a complete portfolio of zero-emission vehicles (ZEVs), establish a new supply chain to support this portfolio, expand production capacity, and achieve a substantial reduction in production costs. In terms of product and solution development, OEMs need to reimagine product designs and create new product lines tailored for the zero-emission truck market. This should include new platform strategies that emphasize key powertrain options and specifications, such as power output, battery sizes, and payload capacity. OEMs must strike a balance between offering a competitive new product lineup across essential market segments and managing development costs and operational complexity.

The adoption of zero-emission trucks has grown significantly since 2020, a time when internal combustion engine (ICE) vehicles dominated the market. By 2030, the industry is expected to undergo a major transformation. In North America, battery electric trucks (BETs) are forecasted to capture about 20% of the market, reflecting the logistics sector’s increasing shift toward electrification. In China and Europe, BETs are projected to account for around 27% of truck sales, driven by strong regulations and significant investments in charging infrastructure. Meanwhile, fuel cell electric trucks (FCETs) are also gaining momentum, albeit at a slower pace. The rise of FCETs offers a complementary solution for zero-emission transportation, especially in scenarios requiring longer ranges and quicker refueling. Together, these developments demonstrate a substantial move toward cleaner technologies, spurred by strict emission standards, advancements in technology, and growing demand for sustainable logistics.

The global truck market can be divided into six main use cases, with long-haul, line-haul, and distribution being the most significant contributors to emissions. To address the diverse needs of customers, both standard and extended-range models will be essential for these segments. Innovations tailored to trucks will play a key role in differentiating the market by extending range, lowering costs, and enhancing charging speed. Through 2030, three key technological factors will drive the adoption of battery electric trucks (BETs). Despite the challenge of higher upfront costs for BETs, the total cost of ownership (TCO) strongly supports the transition to electrification. The main cost factor is the battery cell, making BETs more expensive to invest in compared to traditional internal combustion engine (ICE) vehicles. Achieving economic sustainability will require effective management of TCO and depreciation costs.

Starting from 2025, battery electric trucks (BETs) are expected to deliver total cost of ownership (TCO) advantages across multiple use cases, particularly for applications where mileage and payload efficiency are critical. Achieving these benefits will rely on competitive energy prices and charging costs. The efficiency of BETs and effective use of charging infrastructure are key factors influencing TCO. Stricter CO2 regulations, along with favorable TCO across regions and use cases, will accelerate the shift to electrification. Major drivers of this transition include energy costs and efforts to reduce carbon emissions. By 2030, more than 20% of transportation is projected to be electrified, led by the adoption of heavy-duty vehicles and urban buses. By 2040, BETs are expected to dominate the market, capturing a 90% share.

As the trucking industry navigates the complexities of decarbonization, achieving zero-emission mobility demands not only technological advancements but also innovative approaches to sustainability. Companies that embrace modularity, durability, and eco-friendly solutions will play a crucial role in shaping this transition. e.Volution GmbH serves as a beacon of sustainable innovation, demonstrating how the transition to zero-emission trucking can embrace durability and efficiency while minimizing environmental impact. By developing electric vehicles (EVs) with modular components and an aluminum-based chassis, e.Volution extends vehicle lifespans up to 50 years, reducing waste and fostering circular economy practices. The company’s integration of fuel cell range extenders with battery electric drives enables long-distance capabilities without compromising eco-friendliness. Collaborating with academic institutions like RWTH Aachen University, e.Volution advances reassembly processes for periodic upgrades, ensuring vehicles remain technologically relevant and cost-effective. These initiatives highlight the company’s pivotal role in addressing the challenges of decarbonization, offering scalable, sustainable solutions that align with industry needs and environmental goals.

Article by: Asst. Prof. Suwan Juntiwasarakij, Ph.D., Senior Editor & MEGA Tech