Aug 29, 2025

[Workshop] Extended Range Electric Vehicle (EREV) experience by DHL and its role in road transport decarbonization

Thursday, July 31st, 2025

DHL, in collaboration with Scania, has launched a solution aimed to bridge the gap between the need of road freight transport decarbonization, the current electric truck capabilities and the availability of charging infrastructure: the Extended Range Electric Vehicle (EREV). This technology, which combines a fully electric powertrain with a small fuel-powered generator used solely to recharge the battery, has demonstrated exceptional performance and carbon savings in operations. 

Aim of the workshop  

• DHL to present their experience with the EREV in operations and the potential of the solution to support road transport decarbonization. 

• Share the vehicle classification regarding EUROVIGNETTE and CO2 Standards of HDVs and how a proper recognition under these pieces of legislation could support reaching TCO parity/benefits for an affordable road transport decarbonization. 

• Gather feedback and input from ALICE members to understand if and how this technology should be positioned in ALICE decarbonization roadmap and in the exchanges with the EC in relation to the related legislative files and future R&I programmes. 

Technology – Electric Truck with Fuel Powered Range Extender   

DHL Group and heavy vehicle manufacturer Scania have collaboratively developed an electric truck equipped with a fuel-powered generator that generates electricity to recharge the batteries. This innovative vehicle, known as the EREV, enables a transition to battery-electric road transport without the need to wait for a comprehensive charging network.

• Vehicle Type: Battery-electric truck with fuel-powered Range Extender (REX). 
• Powertrain: 230 kW electric motor (peak: 295 kW) + 416 kWh battery. 
• Range: 650–800 km (battery + generator). 
• Fuel-Powered Generator: 120 kW, petrol-fueled; cannot directly power the wheels, unlike traditional hybrids. 
• Operation: Primarily electric; generator acts only as backup. 
• Top Speed: 89 km/h | Cargo: Swap body with up to 1,000 parcels. 

Key result: In a 22,000 km pilot, DHL operated the vehicle 91.9% on grid-charged electricity, achieving a 90% CO2 reduction vs. diesel — nearly 16 tonnes saved during the test. 

Implications for Eurovignette and CO₂ standards 

Eurovignette 

• The EREV is currently not recognized under the Eurovignette Directive and is classified as emission class 1, resulting in the highest toll charges, despite delivering a 90% tailpipe CO₂ reduction. 
• DHL proposes the creation of a new emissions class (e.g. class 4b) allowing for proportional toll reductions based on VECTO-certified CO₂ savings (e.g. 90% reduction = 90% toll discount). 
• Without such recognition, achieving a competitive Total Cost of Ownership (TCO) for EREVs is difficult, which undermines their deployment as a transition technology. 
• Current classes (such as class 4 for low-emission vehicles) are not easily accessible and only allow for limited toll reductions (up to 50%, often lower in practice). 
• VECTO certification is essential to enable recognition and proportional toll adjustment. 

CO₂ Standards 

• The EREV can contribute to OEMs’ average fleet emissions reductions under the HDV CO₂ standards, provided it obtains a VECTO certificate. 
• A vehicle with a 90% VECTO-certified reduction would count as such in the manufacturer’s fleet average. 
• No legislative changes are foreseen, but the VECTO tool is critical: 
• For enabling toll recognition under the Eurovignette. 
• For supporting OEM compliance under the CO₂ Standards framework. 

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