On 22 May 2025, Dhl announced the operational testing of an Extended Range Electric Vehicle at the OECD’s International Transport Forum in Leipzig. The truck, developed by Scania, is designed to extend the range of electric traction through a hybrid solution. It features a 230 kW electric motor (with a peak power of 295 kW), powered by a 416 kWh battery and supported by a 120 kW diesel generator. The generator is used solely to recharge the batteries in critical moments, such as during cold weather or when charging stations are unavailable or out of service. The diesel engine is not connected to the drivetrain, distinguishing the Erev from conventional hybrid trucks.
During the presentation of the vehicle, which hauls 10.5-metre swap bodies, Dhl shared initial results from its use in parcel transport between Berlin and Hamburg. In its first hundred days of operation, the truck travelled around 22,000 kilometres, delivering performance comparable to that of a fully electric vehicle but with greater operational flexibility. The generator was used in only 8.1 per cent of the distance covered, resulting in over 90 per cent less CO2 emissions compared to a traditional diesel truck. In practical terms, this translates into nearly 16 tonnes of CO2 avoided during the trial period. From an operational perspective, the tractor unit can carry around one thousand parcels and tow a trailer.
According to Tobias Meyer, chief executive officer of Dhl Group, this is a pragmatic response to current infrastructure limitations. “We all want fewer emissions and more electric mobility. But we know the transition will take years, because the power grids and charging infrastructure are not yet ready. We can’t afford to wait: we need solutions like the Erev and swift political decisions to support these bridging technologies.”
The trial has also highlighted another key factor: reliability. The truck has regularly covered routes of around 250 kilometres, using almost exclusively electricity from renewable sources. Dhl states that thanks to the backup generator, the Erev ensures reliable logistical planning, eliminating the risk of vehicle downtime due to a lack of charging stations. The company is now awaiting the next generation of Erev vehicles, which will feature improved performance thanks to a 520 kWh battery and software capable of automatically limiting the generator’s use, thereby setting a cap on emissions.
Dhl views this first trial positively but notes that it is not enough. Regulatory recognition is needed to make Erevs a viable large-scale alternative. The company has issued a call for European regulations — starting with the calculation of motorway tolls and fleet emissions — to take into account the actual emissions of vehicles. The introduction of a specific emissions class for vehicles with proportionally reduced emissions, based on certified values, would allow Erevs to compete fairly with the most sustainable solutions already recognised. The new German government has already included support for Erevs in its programme, and Dhl is urging rapid implementation. “The technology is ready. We are ready. Now it’s up to policymakers,” Meyer concluded.
