With the advent of electric trucks, logistics is also changing its face, operating methods and schedules. This has happened along the Brenner motorway, the scene of a four-week test involving MAN’s battery-powered (BEV) eTGX trucks, which were used for night-time crossings of the Austrian section, prohibited for diesel-powered trucks, even those of the latest generation engines.

The choice of the Brenner route for the pilot project with electric trucks was not accidental. In fact, over 70% of trade flows between Italy and the countries of the European Union pass along this route. In figures, this means around 2.37 million lorries every year and more than 50-53 million tonnes of goods.

The aim of the joint MAN-Dettendorfer test – a family business based in Raubling, a long-standing partner of the Bavarian manufacturer and a pioneer in sustainable logistics – is to ease traffic on the Brenner Pass. But also to avoid concentrations and congestion of transport vehicles – such as access for groups of 300 vehicles per hour, known as “dosages” – reduce CO2 emissions and noise pollution, and ensure greater continuity of supply, especially during collective holiday periods, when car traffic adds to that of industrial vehicles.

Night-time transport with electric lorries along the Brenner route has been theoretically possible since 2021. However, until now, there have been no vehicles capable of completing the mission and no charging infrastructure suitable for long-distance trucks. With the MAN eTGX, which has been in series production at the Munich plant since last June, it is possible to cover up to 800 kilometres daily with a single intermediate recharge, regardless of weather conditions.

Thanks to the exemption from the night-time driving ban on the A12 (Inntal) motorway in Tyrol, eTrucks can operate without time restrictions on the entire cross-border route between Germany and Italy and vice versa. This is a particularly attractive solution for the cold chain logistics sector, for the transport of pharmaceutical products under temperature-controlled conditions (ATP) and for time-critical supply chains.

For the environment…

Crossing the Brenner Pass at night is potentially a strategic solution that can have positive effects on the environment, journey times and operating costs.

According to a simulation, the use of around 300 electric lorries at night can reduce waiting times at the Kufstein border crossing during the day by one hour. In addition, eTrucks make a substantial contribution to climate protection, with an average annual saving of around 95 tonnes of CO2 per vehicle, based on a total mileage of around 110,000 kilometres. This means that with 300 vehicles in service every day, 28,000 tonnes of carbon dioxide are avoided per year, an amount equivalent to the emissions of a small town.

Noise pollution is also drastically reduced, as demonstrated by the 12-decibel difference during acceleration between a BEV and a truck with an internal combustion engine. In addition to the environmental benefits, there are also economic advantages for operators with eTrucks in their fleets.

…and your wallet

This applies in particular to companies whose vehicles travel more than 110,000 kilometres on German motorways – where there is a total exemption from tolls – which achieve savings of up to €60,000 per year, and those operating on cross-border routes. For example, on the A13 in Austria, electric vehicles benefit from a reduction of up to 75%, especially at night. In Italy, on the other hand, the toll differences between diesel vehicles and BEVs along the Brenner route to Bolzano are still minimal.

Over a three-year period, the typical period of use for transport vehicles in logistics, toll savings provide an overall economic advantage on TCO (Total Cost of Ownership) of more than 15% compared to diesel vehicles. Added to this are lower energy and maintenance costs, exemption from road tax and the growing availability of charging infrastructure along the route. Practical examples show that charging costs are around €0.41/kWh at night in Raubling (Germany) and around €0.38/kWh in Bolzano. In addition, energy recovery from electric vehicles along the downhill section of the mountain route can reach up to 40%, which translates into greater powertrain efficiency and extended operating range.

The technical differences explained by the expert

The numerous advantages of using eTrucks on the Brenner route were discussed by Allestimenti & Trasporti during an exclusive interview with Roman Sitte, Senior Vice-President and Head of Sales Europe at MAN Truck & Bus.

“‘With the support of one of our long-standing customers, the Dettendorfer Group,” explains Sitte, “we have tried to demonstrate, in black and white, the numerous benefits of using electric heavy goods vehicles during the night in today’s economic and environmental scenario. The Austrian section of the Brenner motorway, characterised by a high and uninterrupted flow of traffic in a steep, enclosed valley and by night-time driving bans on diesel lorries, is the ideal location for a pilot project of this kind. In the current situation, traffic congestion, the quota-based entry of 300 articulated lorries, delivery delays, air pollution and noise pollution are a burden for everyone: residents, drivers, logistics operators and customers”.

Are eTrucks the ideal solution to all these problems?

“There is still a lot to be done at European level. It is a fact that there are still major disparities within the EU in terms of the regulatory framework, policies to encourage the purchase of zero-emission lorries, and the development of electricity grids and public charging networks. All this creates a climate of uncertainty among transport companies, which operate on tight profit margins.“

What are the main arguments for convincing logistics operators to purchase electric vehicles? Business case simulations?

“Absolutely. It’s something we do every day when we talk about e-mobility. However, the most compelling motivation comes from our customer’s clients, who are committed to meeting CO2 and other environmentally impactful gas reduction targets, in line with the recommendations of climate science (Science Based Target Initiative). And we believe that it is also worthwhile from an economic point of view. Over a three-year period, the use of eTrucks for long-haul missions can be 15% more cost-effective than a traditional diesel truck. Obviously, a lot depends on the routes, the cost of fuel and electricity, and the possible installation of a photovoltaic system on site. Overall, the operating costs per kilometre of a BEV – relating to energy, maintenance and repairs – can be 50% lower than those of a traditional diesel truck. Not to mention the advantages associated with motorway tolls”.

From an operational point of view, how do eTrucks fare on the Brenner route?

“MAN has devoted considerable research and development efforts to maximising the energy recovery of eTGXs when driving downhill. On a hilly route such as the Brenner motorway, we recorded average consumption of 93 kWh/100 km for a standard 40-tonne articulated lorry. On downhill sections, it is possible to recover up to 150 kWh, which means extending the operating range by another 160 kilometres without resorting to recharging.”

Bolzano’s first one-megawatt charging hub for heavy-duty trucks

A new era in heavy transport is dawning on the Brenner motorway. Last May, in fact, the first 1 MW charging point in Italy for heavy-duty vehicles, built by Alpitronic, was inaugurated in the Firmian park near the Bolzano Sud toll gate.

The Power Unit, consisting of eight modules with a maximum total power of 1 MW, is the heart of the system, which powers two dispensers. To date, there are three charging spaces available. The first column, closest to the Power Unit, features the traditional CCS2 (Combined Charging System) connector with a maximum power output of up to 600 kW, as well as the new 1,000 kW MCS (Megawatt Charging System) connection.

The main advantage of ultra-fast charging for heavy-duty vehicles equipped with batteries with installed power ratings between 300 and 600 kWh is the reduction in downtime in relation to the increase in operating range. Alpitronic’s MCS allows the tractor unit of an articulated lorry to be recharged within 45 minutes of the mandatory break required by law every four and a half hours of driving. In fact, it takes just 30 minutes to recharge a truck equipped with 500 kWh batteries, half the time required by the systems available to date.

Lots of advantages

This, in turn, allows for an enhanced range of 500 kilometres, which varies depending on the altitude profile of the route and the outside temperature. The second dispenser at the Bolzano facility houses two 600 kW CCS2 connectors. The novelty in this case is not the connector, but the maximum power output. There is another aspect that makes the Bolzano South hub interesting for the industrial vehicle sector. The presence of a power unit with an output of 1000 kW will allow three vehicles to be charged quickly at the same time, with the available 1000 kW being distributed between them.

Finally, there is another special feature. Thanks to the 2,000 kVA transformer installed by Autostrada del Brennero, the facility is already equipped to accommodate a second 1 MW charging system in the future, thus doubling the station’s capacity.

Find out more in the next issue of Allestimenti & Trasporti! To subscribe or receive further information, please click here: https://allestimenti-trasporti.it/richiesta-informazioni/
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