Exchange for more BETs

Zero-emission trucks have long promised lower operational costs and a reduced carbon footprint, but industry leaders and academics require more than theoretical benefits; they require quantified, real-world proof. The completed "Exchange for more BETs" project, a transatlantic collaboration between Sweden and the United States, was established to provide exactly that. By analyzing live operational data from early adopters, the initiative confirmed that battery electric trucks (BETs) match or exceed diesel reliability, demonstrating minimal downtime and negligible battery degradation even under demanding conditions. Crucially, the project revealed that while the Total Cost of Ownership (TCO) for local distribution still relies on subsidies to close a 10% gap, electric line-haul operations—when combined with strategic depot charging—have already achieved cost parity with diesel.

The transition to zero-emission logistics is a global challenge. While the market for electric heavy-duty vehicles is young, both Sweden and the United States positioned themselves at the forefront of this technological shift.

Both CALSTART and Lindholmen Science Park have been involved in many early deployments seeking to study how these vehicles perform in real-world fleet operations. Researching the results of past and current deployments and presenting the learnings from each country will help speed the transition to zero-emission trucks and the growth of clean transportation in general. 

Led by CALSTART in the US and Lindholmen Science Park in Sweden, the project facilitated cross-border knowledge sharing from 2023 to 2025. By analyzing extensive real-world deployments—including Sweden's REEL project, which deployed 70 electric trucks ranging from 16 to 74 metric tons across varied applications—the initiative successfully mapped operational strategies, infrastructure solutions, and the policy requirements necessary to accelerate the shift away from fossil fuels.

Results and Insights

The data collected from operators running vehicles in conditions ranging from urban distribution to heavy timber transport and long-haul logistics provided several definitive insights.

Operational Reliability and Performance

The physical performance of the trucks is no longer a limiting factor. The project tracked vehicles operating in demanding climates, including northern Sweden where temperatures drop to -30°C.

• High Uptime: Most prototype and early-production electric trucks were out of operation for an average of only five days per year over a three-year period.
• Battery Longevity: One notable vehicle in the project logged over 500,000 miles in a two-shift configuration between Gothenburg and Helsingborg, demonstrating no significant battery degradation despite heavy daily utilization.
• Operational Efficiency: The majority of transport companies reported that their overall logistical efficiency was unaffected. In some urban cases, operators successfully extended delivery windows into the night due to the quiet nature of the electric drivetrains.

The Economics of Electrification (TCO)

The shift to electric fleets requires transitioning from an OPEX-heavy business model to a CAPEX-heavy one, driving haulers to negotiate longer transport contracts (shifting from two years to up to five years) to balance the initial investment risk. The Total Cost of Ownership is highly sensitive to how and where trucks are charged, as well as the availability of state subsidies.

• Local and Regional Distribution: With state subsidies applied to both the vehicle and infrastructure, the TCO gap is approximately 10% to 11% higher than diesel. Without subsidies, this gap widens to roughly 20%.
• Line Haul: When operating on longer routes and utilizing subsidies, the TCO for electric trucks is actually 1% cheaper than diesel, reaching true cost parity. Without subsidies, it is only 3% to 5% more expensive.
• Maintenance: Contrary to the assumption that EVs immediately slash maintenance costs, early deployment costs have remained relatively flat. While 25% of operators achieved lower maintenance costs, another 10% saw an increase, driven largely by the mandatory "gold service contracts" required by OEMs and the costs associated with reskilling workshop personnel.

Infrastructure Strategy is Critical

Control over charging infrastructure is the primary lever for a successful business case.

• Depot Charging is Essential: Relying entirely on public charging destroys the economic viability of electric trucks. Because public infrastructure pricing is currently aligned with passenger car rates, utilizing 100% public charging pushes the TCO to roughly 32% higher than diesel.
• Grid Independence: To secure predictable energy costs, multiple operators are investing in localized energy production. Approximately 15% of the studied operators have connected solar power directly to their charging infrastructure, and a growing number are planning to integrate battery energy storage systems (BESS)—potentially utilizing second-life batteries retired from the trucks themselves.

The Impact of Policy

The data proves that policy acts as the ultimate catalyst or bottleneck. During the project, Sweden reduced its renewable fuel mandate from 26% to 6%. This sudden policy shift drastically lowered the cost of diesel, temporarily weakening the immediate economic case for electric adoption in the country compared to nations like Germany or Norway. However, upcoming European mandates—such as CO2-differentiated road tolls and the Emissions Trading System (ETS) for transport—are projected to firmly tip the economic scales permanently in favor of electric trucks by increasing the operational cost of diesel alternatives.

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