REBOOT · Project

Retrofit Kit Converts Old Diesel Buses to Full Electric at 80% Lower Fuel Cost

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Imagine you run a city bus fleet and your older diesel buses are being banned from low-emission zones. Buying brand-new electric buses costs a fortune. MAGTEC built a retrofit kit that rips out the old diesel engine and drops in an all-electric drive system — same bus, zero emissions, 160 km range. It's like swapping the engine in your car for an electric one instead of buying a whole new vehicle, and it pays for itself within five years through fuel savings alone.

By the numbers

80%

Reduction in fuel operating cost for bus operators

€166,000

Target system price per bus

5 years

Payback period for operators

160 km

Range per charge for 18 tonne bus

500+

MAGTEC electric drives already sold

2.2 tonnes

Maximum weight of retrofit system (matches diesel drive)

130 kg

Weight saving in powertrain vs competitors

14%

Reduction in battery size, weight and cost

22 years

MAGTEC track record in electric drive systems

The business problem

What needed solving

City bus operators face a painful dilemma: their older diesel buses are being banned from expanding Low Emission and Zero Emission Zones, but replacing entire fleets with brand-new electric buses requires massive capital expenditure. Operators need a way to make existing buses compliant and cost-effective without writing off vehicles they have already invested in.

The solution

What was built

MAGTEC developed a complete retrofit all-electric drive system, battery pack, and recharger for 18 tonne buses weighing under 2.2 tonnes with 160 km range. The project delivered a demonstration of off-vehicle charging and a marketing rollout plan including exhibitions and demonstrations.

Audience

Who needs this

Municipal transit authorities operating aging diesel bus fleets in emission-restricted zonesPrivate sightseeing and tour bus operators in European city centersBus fleet leasing and management companies seeking asset life extensionRegional transport operators facing Low Emission Zone compliance deadlinesShuttle service operators at airports, campuses, and business parks

Business applications

Who can put this to work

Public Transit Operations

enterprise

Target: Municipal bus operators and transit authorities

If you are a city transit operator dealing with aging diesel fleets facing Low Emission Zone restrictions — this project developed a retrofit all-electric drive system for 18 tonne buses that delivers 80% reduction in fuel operating cost. The system weighs less than 2.2 tonnes (matching diesel drive weight) and offers 160 km range, meaning no route compromises. At €166,000 per bus with a 5-year payback, it costs a fraction of buying new electric buses.

Tourism & Sightseeing Transport

SME

Target: Sightseeing bus operators and tour companies

If you are a sightseeing bus operator looking to go green without replacing your fleet — this system was already commercially demonstrated in the city sightseeing bus market. The retrofit delivers zero emissions for urban tourist routes, helping you meet city center restrictions. With 500+ MAGTEC electric drives already sold to bus and truck manufacturers, the technology is proven in real-world operation.

Fleet Management & Vehicle Leasing

mid-size

Target: Bus leasing companies and fleet management firms

If you are a fleet management company trying to extend the economic life of bus assets while meeting emission targets — this retrofit converts existing buses to full electric operation, preserving your capital investment. The 80% fuel cost reduction and sub-2.2 tonne system weight mean operators retain payload capacity. The €166,000 price point with 5-year payback makes the business case straightforward for fleet-wide rollout.

Frequently asked

Quick answers

What does the retrofit system cost and what is the payback period?

The target system price is €166,000 per bus. MAGTEC projects a payback to the operator within 5 years, driven primarily by an 80% reduction in fuel operating costs. This is significantly cheaper than purchasing a new electric bus.

Can this scale to large urban bus fleets?

MAGTEC has already sold 500+ electric drives to bus and truck manufacturers and has 22 years of electric drive system design and manufacturing experience. The system was designed for standard 18 tonne buses, which covers the majority of urban transit fleets. Commercial demonstration has already occurred in the sightseeing bus segment.

What about intellectual property and licensing?

MAGTEC developed this as a proprietary product under the SME Instrument (Phase 2), meaning IP sits with the company. Based on available project data, the system is offered as a direct product to bus operators, not as a licensed technology. Interested parties would purchase the retrofit system from MAGTEC.

Does it meet emission zone regulations?

The system produces zero tailpipe emissions, which exceeds any Low Emission Zone or Zero Emission Zone targets currently in force. This future-proofs retrofitted buses against tightening urban emission regulations across European cities.

What are the performance specs compared to diesel?

The retrofit system weighs less than 2.2 tonnes — matching the weight of the diesel drive it replaces. It delivers 160 km range per charge. MAGTEC achieved a 130 kg weight saving in the powertrain and a 14% reduction in battery size, weight, and cost compared to competitors.

How long does the retrofit take and what about charging?

Based on available project data, the project included a deliverable specifically for demonstration of off-vehicle charging infrastructure. The system includes the drive, battery pack, and recharger. Specific installation timelines were not detailed in the available data.

Consortium

Who built it

This is a single-company project by MAGTEC (Magnetic Systems Technology Limited), a UK-based SME that is the country's largest supplier of hybrid and electric drive systems. The 100% industry consortium with zero academic partners signals this is a commercial product development effort, not basic research. MAGTEC has 22 years of track record and 500+ electric drives sold, making them an established player rather than a startup. The SME Instrument Phase 2 funding confirms the EU assessed this as a close-to-market innovation with strong commercialization potential. For a business buyer, MAGTEC represents a credible supplier with proven manufacturing capability and an existing customer base among bus and truck manufacturers.

MAGNETIC SYSTEMS TECHNOLOGY LIMITEDCoordinator · UK

How to reach the team

MAGTEC (Magnetic Systems Technology Limited), UK — contact via company website or SciTransfer introduction

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Next steps

Talk to the team behind this work.

Want to explore electric retrofit options for your bus fleet? SciTransfer can connect you directly with the MAGTEC team and provide a tailored briefing on how REBOOT fits your operational requirements.

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