TCO of electric trucks: when is the switch worthwhile?

The electrification of transport and logistics fleets is a key step towards more sustainable mobility. But for many companies, the question is: when is it actually worth investing in electric trucks and vans? A detailed look at the total cost of ownership (TCO) provides answers.

What is the total cost of ownership (TCO)?

The TCO includes all costs incurred over the entire service life of a vehicle. This includes not only the purchase costs, but also operating costs such as maintenance, energy consumption and government subsidies.

A study by the ICCT shows that e-trucks are not only more sustainable in the long term, but can also be financially competitive or even more cost-effective. The study compares the TCO of diesel and electric trucks and shows that the higher acquisition costs of electric trucks are amortized through lower operating costs - usually within 4 to 6 years. Lower energy costs and lower maintenance costs are crucial for this. Especially in urban areas with stop-and-go traffic, e-trucks benefit from their lower energy consumption and lower maintenance costs.

Overall, the study shows that the switch to electric trucks is not only environmentally friendly, but also makes economic sense:

• E-trucks are expected to be the most cost-effective enablers of decarbonization for most truck classes by 2030.
• In all truck classes, e-trucks that draw their energy from the European electricity grid will have the lowest total cost of ownership.

Let us now look at the individual cost factors in detail.

1. acquisition costs & subsidies

Electric vehicles are often more expensive to purchase than comparable diesel models. The higher investment costs pose a particular challenge for companies that want to convert their fleet to sustainable drive systems.

To facilitate the market launch and operation of electric commercial vehicles, there are various funding opportunities in Germany. However, government support is subject to constant change. There is currently no uniform federal funding for electric trucks, but some federal states offer targeted programs that create financial incentives. These include direct subsidies, tax relief or discounted financing models.

As the funding landscape is developing dynamically, companies should regularly check which subsidies and tax benefits are currently available. In addition to government support, alternative financing models can also help to reduce investment costs. Leasing or pay-per-use models offer companies the opportunity to use electric trucks without high initial investments and at the same time to react flexibly to operational requirements.

Careful planning and the use of suitable funding and financing offers can make the switch to electric commercial vehicles more economically attractive and profitable in the long term.

2. energy costs: electricity vs. diesel

The cost of electricity per kilometer is generally lower than the cost of diesel, which can lead to considerable savings in the long term.

Intelligent energy management is crucial to minimizing the operating costs of electric fleets and ensuring an efficient, reliable energy supply. With time-controlled charging strategies, electric trucks can be charged preferentially when electricity tariffs are low or there is an oversupply of renewable energy. This reduces costs and increases the proportion of green energy. In addition, dynamic control makes it possible to distribute the charging power in order to avoid peak loads and reduce the load on the power grid.

The integration of decentralized energy sources such as photovoltaic systems and battery storage further optimizes the energy supply and makes companies less dependent on expensive grid electricity. Intelligent charging strategies are therefore a key component for the economical and sustainable electrification of commercial vehicle fleets.

3. maintenance and repair costs

Maintenance costs play a decisive role in the total cost of ownership of commercial vehicles. Electric vehicles have a clear advantage here, as they have fewer moving parts and are therefore less susceptible to wear and tear. In contrast to diesel vehicles, there is no need for costly maintenance work such as oil changes, clutch replacements or the replacement of exhaust systems and injection systems.

Another important factor is recuperation, i.e. energy recovery during braking, which significantly reduces mechanical brake wear. This means that brake pads and discs need to be replaced less frequently, which also helps to reduce costs.

Overall, this lower maintenance effort means that the maintenance costs of electric commercial vehicles can be up to 50 % lower than for comparable diesel models.

4. residual value and service life

Battery technology is constantly evolving, which leads to a continuous improvement in the service life of batteries. Thanks to intelligent charging and energy management, electric trucks can be charged in a targeted manner that protects the battery. At the same time, the charging cycles can be monitored precisely so that signs of wear or potential failure can be detected at an early stage and appropriate measures can be taken.

In this way, the residual value of batteries can be increased, especially if they continue to be used after their first use in the so-called “second life”. Some manufacturers have also introduced battery leasing models to counteract the risks for consumers and companies while reducing the financial burden. These models make it possible to use batteries without buying them outright, which is a flexible and sustainable solution.

5. application profiles and ranges

Electric trucks are already an economically viable solution for urban delivery traffic and for routes with fixed schedules and predictable charging times. In these areas of use, they can make the most of their advantages, such as low operating costs and zero emissions. Electric trucks are also increasingly practicable for regional and medium-distance transport (up to approx. 500 km).

For real long-distance use (>800 km), electric trucks still face challenges, but the technology is developing rapidly. New battery generations with higher energy density and shorter charging times, as well as the expansion of a nationwide fast-charging network, will significantly improve the possibilities for using electric trucks over long distances in the coming years.

Conclusion: When is the switch worthwhile?

• Companies with short-haul fleets and urban logistics are already benefiting from the lower operating costs and existing funding opportunities. Especially in cities, where low emission zones are becoming increasingly important, e-trucks offer economic and regulatory advantages.
• Companies with their own charging infrastructure can achieve considerable cost savings through optimized energy management. The integration of photovoltaic systems or battery storage systems reduces dependence on grid power and lowers energy costs in the long term.
• Rising diesel prices and falling battery costs are increasingly shifting the economic balance in favor of electromobility. As the ICCT study found, electric trucks will be the most economical solution in most areas of application by 2030.

It is worthwhile for companies to carry out an individual TCO calculation and take intelligent charging management solutions into account in order to achieve the maximum economic advantage.

Are you thinking about switching? Our experts will be happy to advise you on the best strategies for your e-fleet!