Solaris shares update on electric bus retrofit scheme

At the recent Mobility Move event in Berlin, Solaris provided an update on it its retrofit programme for Europe’s aging electric bus fleet, which was launched just a few months ago. According to Sustainable Bus, retrofit contracts have now been agreed for a total of 170 Urbino vehicles. Specifically, this includes 105 units for BVG in Berlin, 26 units in Kraków, 18 in the Romanian city of Cluj-Napoca, ten buses in Hamburg, eight in the Polish city of Jaworzno, two in Brussels, and one vehicle in Warsaw.

The programme targets approximately 1,325 battery-electric buses delivered by Solaris between 2013 and 2019. This represents 22 per cent of the Solaris-branded battery-electric buses currently on the roads. The goal is to prevent these ageing electric buses from being phased out prematurely. Under the label ‘Zero-Emission Vehicle Retrofit’, the Polish manufacturer offers the replacement of key components – primarily batteries – to extend the operational life of these vehicles.

When the programme was introduced in December, Solaris stated that it aims to provide customers with earlier generations of electric buses an ‘effective solution’ to ensure these vehicles remain competitive in the public transport sector. To achieve this, the company has standardised the replacement of degraded batteries and other components as part of its service offering. Owners of electric buses are thus given the opportunity for ‘post-warranty replacement of EV components with new ones,’ as the manufacturer explains. The new service is not limited to battery-electric buses but also applies to battery-powered trolleybuses and, in the future, Solaris’ hydrogen buses.

It is evident that Solaris is not the only electric bus manufacturer addressing the challenge of supporting early customers with underperforming electric buses. On the one hand, battery capacity diminishes over time due to ageing; on the other, rapid technological advancements in recent years have led to significantly improved and more efficient technology platforms in newer-generation electric buses. Daimler Buses, for example, has already introduced comprehensive battery services for the eCitaro since spring and, from 2026, will also offer upgrades to the latest battery generation for older vehicles.

For comparison: the eCitaro has only been in production since 2018. Solaris, however, began producing electric buses several years earlier, making the issue even more pressing for the Polish manufacturer. To put this into perspective: today, the solo bus Urbino 12 electric offers a maximum total energy capacity of over 600 kWh for ranges exceeding 600 kilometres. Before 2025, the Urbino 12 electric could accommodate a maximum of 520 kWh, and before 2022, this was up to 395 kWh. The manufacturer describes this as a technological evolution ‘taking place in a relatively short time with an unprecedented evolution of the solution defined’. The transition in powertrains is occurring in a relatively short time, leading ‘to technological obsolescence during the normal vehicle exploitation period.’ Solaris aims to counteract this and extend the lifespan of electric buses, though the pricing for this service remains undisclosed.

In practice, customers receive comprehensive support during the component replacement process. According to Solaris, the service includes ‘a thorough case analysis, calculation, and complete documentation, through the collection of previously used batteries, to the installation of new ones.’ As part of the retrofit, the company also ensures that other necessary electrical components are replaced, the thermal management system is upgraded (or installed), and the battery management system is updated. Additionally, Solaris guarantees that the modified batteries are compatible with the customer’s existing charging infrastructure.

Furthermore, customers can choose between LFP, NMC, or LTO battery technologies for the newly installed batteries. As stated by the company in December, the optimal battery solution is offered to meet specific customer requirements. When preparing the offer, additional factors are considered, focusing primarily on the targeted battery lifespan, charging and usage methods, daily energy requirements, and, of course, costs.

sustainable-bus.com