DHL Freight, along with the BMW Group and other partners, has put two trucks into real operation. This pilot test is part of the European H2Haul project promoting hydrogen mobility. The goal is to evaluate the practicality of hydrogen fuel cells for heavy-duty trucks in everyday operations. This practical test marks an important milestone in advancing hydrogen technology in transport logistics.
Strong Partners, One Goal: Zero-Emission Logistics
As a pioneer in eco-friendly logistics, DHL Freight is committed to contributing to the development and testing of emission-free vehicles. To this end, we are open to different drive systems – and to forward-looking cooperations with like-minded partners who share our vision of making the logistics of the future as low-emission as possible. H2Haul is another example of our dedication to sustainability.
H2Haul
Funded by the EU’s Clean Hydrogen Partnership, the H2Haul project is testing and researching hydrogen trucks with fuel cell drivetrains under realistic conditions. The project is intended to pave the way for the commercialization of fuel cell trucks in Europe. It started in 2019 and will put 16 heavy-duty hydrogen fuel cell electric vehicles (FCEVs) on the road at four locations in Europe. FCEVs use hydrogen differently than trucks with H2 combustion engines (Internal Combustion Engine – ICE). FCEVs generate electricity in a fuel cell, while ICE hydrogen vehicles combust the hydrogen with oxygen from the air. DHL Freight is also testing H2-ICE technology. This is part of the HyCET project.
For the German branch of H2Haul, DHL Freight is cooperating with BMW Group (the consortium leader), IVECO, and TEAL Mobility as an associated partner of the consortium. IVECO designed the two trucks and uses Bosch fuel cell technology. TotalEnergies has set up new hydrogen filling stations in Leipzig and Hormersdorf, which are maintained by TEAL Mobility, a joint venture between TotalEnergies and Air Liquide. DHL Freight contributes its logistics expertise by operating the trucks as a shuttle service for BMW during the day and as a regular service between Leipzig, Landsberg (Saalekreis), and Nuremberg at night.
- Vehicle drive: hydrogen fuel cell powered by an integrated hydrogen tank. The fuel cell generates electricity to charge the truck battery while driving.
- Range: over 700 km
- Refueling time: about 25 minutes
- Daily mileage in regular operation: around 700 km
How Suitable Is the Hydrogen Fuel Cell for Heavy Goods Vehicles?
To find this out is the objective of the German H2Haul project. DHL Freight is taking on the role of the user. Thus, we are gaining firsthand experience with everyday operations, including consumption, operability, performance, driving behavior, driving experience, and comfort.
For DHL, two questions are paramount:
- Can hydrogen fuel cell technology significantly contribute to decarbonizing the logistics processes of DHL Freight and DHL Group?
- Can the trucks handle the daily challenges of our logistics operations?
700 Kilometers Per Day in Regular Operation
DHL Freight is testing the two FCEV trucks in shuttle operations for BMW. During the day, the trucks travel between the DHL Freight terminal in Landsberg and the BMW plant in Leipzig. The 80-kilometer route is run several times a day, depending on the order volume. During the project, an additional scheduled nighttime run will be added to the DHL network between Landsberg and the DHL Freight terminal in Nuremberg. This route is approximately 600 kilometers long. Together, the two trips add up to around 700 kilometers of daily mileage.
Characteristics of the FCEV Trucks
The trucks do not emit any CO2 while driving, and they are exempt from tolls in Germany and subject to favorable toll regulations in other European countries. Trucks with hydrogen fuel cell drives are half as loud as diesel trucks. They have a range of over 700 kilometers, which is greater than electric trucks but less than conventional diesel trucks. However, operation is not yet completely emission-free. DHL Freight does not yet have access to green hydrogen at the filling stations. This will be made available during the project phase.
A Strong Team Performance is Key to Progress
The practical launch of H2Haul in Germany was a real team effort, both within the consortium and within DHL. The Landsberg terminal employees organized the transports, the legal and data protection departments ensured compliance with German and global regulations, and the DHL Mobility colleagues registered and insured the vehicles. A pioneering project like this can only succeed if all the gears mesh perfectly.
Initial Operating Experience with Hydrogen Technology is Positive
Since H2Haul is a pilot project, initial difficulties with the new technology are normal and expected. Nonetheless, DHL Freight assumes the trucks will operate reliably on the designated routes. The cabin crews confirm these expectations. The drivers are very satisfied with the trucks which are easy to drive. They particularly appreciate the low noise level.
Driver training sessions for the hydrogen trucks held in advance contributed to this positive driving experience. DHL Freight organized a training course with IVECO where colleagues could familiarize themselves with the trucks beforehand. There was also training at the TEAL Mobility filling station in Leipzig as refueling with hydrogen differs from refueling with diesel.
What Is the Next Step After Passing the Practical Test?
Irrespective of the test results, DHL Freight’s overarching goal is to operate as resource-efficiently as possible, regardless of the drive technology employed. As part of DHL’s sustainability strategy, DHL Freight and DHL Group have committed to achieving net-zero emissions by 2050.
A positive test under H2Haul gives DHL Freight a clear chance to make significant progress in decarbonizing road freight transport. We support our forwarding partners in purchasing or leasing hydrogen trucks, and we aim to be a reliable partner for our subcontractors regarding investment decisions in new technologies and sustainability.
H2Haul and HyCET
In addition to the H2Haul project, DHL Freight is participating in the HyCET research project as a logistics partner and user. This project, also led by BMW, involves trucks with H2 combustion engines. As part of HyCET, DHL Freight will test four hydrogen-powered heavy-duty trucks.
Together, these complementary pilot projects promise to greatly increase DHL Freight’s and the entire industry’s knowledge. H2Haul and HyCET provide an opportunity to test the two hydrogen technologies, FCEV and ICE, on the same routes during daily operations. This allows us to clearly identify the advantages and disadvantages of each technology – not only in terms of capacity, efficiency, driving experience, and range, but also with regard to hydrogen consumption in H2 fuel cell and H2 combustion technologies, respectively.
The HyCET trucks from Volvo and Keyou are scheduled to go into operation at the beginning of 2026.
How You Can Benefit from GoGreen Plus
Climate change is the greatest challenge of our time – and it affects all of us. However, it is not equally easy for every industry and every company to reduce their respective ecological footprint. With GoGreen Plus, we offer you the opportunity to reduce emissions in a simple way thanks to insetting – exactly where they occur. Your investment goes 100% into the use of green technologies within our network.
Hydrogen and Other Sustainability Initiatives from DHL Freight
DHL Freight is exploring the potential of hydrogen technology for road freight transport beyond H2Haul and HyCET. For instance, there is the pilot operation of the Paul Hydrogen Power Truck in the German Rhineland. Electromobility is undoubtedly an important way to reduce emissions, which is why DHL Freight uses electric trucks on many routes throughout Europe. Most recently, this has included e-transports for the Hilti Group and tests with e-trucks from BYD. To operate our fleet as sustainably as possible in the short term, we also use emission-reducing HVO fuels, as in our collaboration with the mechanical engineering company Manitou Group.
No matter which path we take toward green logistics, our customers can join us on the journey with GoGreen Plus services. They can also reduce their own Scope 3 emissions at the same time.
Photos: BMW Group
