Tackling the challenges of charging infrastructure for electric buses and trucks.

The framework we work within.

As the global push for decarbonization accelerates, the electrification of heavy-duty vehicles like trucks and buses is emerging as a crucial step toward sustainable transportation. For fleet operators and service stations, this transition brings both opportunities and significant challenges, especially in deploying adequate charging infrastructure to meet the rising demand for electric vehicle (EV) charging.  

Electric trucks and buses are no longer just niche solutions; they are quickly becoming mainstream. The European Union’s regulatory framework, including the Euro 7 emissions standards and the Alternative Fuels Infrastructure Regulation (AFIR), is driving this shift. These policies not only encourage the adoption of zero-emission heavy vehicles but also impose stricter targets for manufacturers and operators.  

In 2023 electric truck sales in Europe nearly tripled, reaching over 10,000 units and accounting for more than 1.5% of total truck sales (European Automobile Manufacturers Association). Similarly, battery electric city buses accounted for 40% of city bus sales in the second quarter of 2024, with 1,616 registered units (CleanTechnica).  

Electric trucks and buses, while requiring investment and careful planning for charging infrastructure, offer exciting opportunities for innovation. With the right expertise and tailored solutions, fleet operators and service stations can turn challenges like grid capacity, charging layout optimization, and logistics management into drivers of progress, accelerating the shift toward efficient, reliable, and sustainable mobility systems.  

The public transport sector is rapidly transitioning to e-buses, with cities across Europe leading the way. 

The gap we face.

Overcoming grid capacity limitations: powering the future of EV transports. 

One of the most significant challenges today is the demand for higher power capacity to support heavy-duty vehicles like e-trucks and e-buses, which require much more power than their passenger vehicle counterparts. To meet these needs, high-power DC chargers – capable of delivering up to 1.4 MW for trucks – and emerging technologies like Megawatt Charging Systems (MCS) are essential for fast, efficient charging.  

As of 2023, Europe had approximately 730,000 public light-duty vehicle chargers, with this number projected to increase to around 2.7 million by 2035 (European Commission). For medium- and heavy-duty trucks, over 300,000 charging points will be required by 2030, compared to the current estimate of roughly 10,000 according to the International Council on Clean Transportation.  

However, the real challenge lies in connecting these charging points to the grid, particularly in remote or industrial areas where infrastructure is often underdeveloped. Ensuring the grid can handle the increased load requires specialized expertise, and the solutions will vary depending on the country and local context. Each location may require tailored infrastructure upgrades, making this process both complex and costly, but also an opportunity for innovation.  

Making room for the future: the space challenge in heavy-duty charging. 

Space presents another critical challenge in the electrification of heavy-duty transport. Charging these large vehicles requires not only sufficient parking but also meticulously planned layouts to ensure they can be accommodated efficiently.  

This challenge becomes even more pressing at service stations along major transport corridors and in urban depots for public buses, where land is often limited. Operators must carefully balance the need for space with operational efficiency. In these high-demand areas, achieving this balance requires detailed, context-specific planning to maximize available space and minimize disruptions, making it a complex task in already crowded urban environments.  

Optimizing charging logistic: aligning routes, schedules and rest periods. 

The logistics of charging are fundamentally different for heavy-duty vehicles than for light-duty cars. These vehicles’ charging needs are directly tied to their routes, schedules, and mandatory rest periods. 

For trucks, ensuring charging stations are aligned with the routes on the Trans-European Transport Network (TEN-T) is crucial for maintaining operational flow. Similarly, public bus fleets require depot charging systems that are seamlessly integrated into their schedules, ensuring that vehicles are always ready for their next shift without disrupting service. 

The key TSG provides.

As the leader in technical services for responsible mobility solutions, TSG is uniquely positioned to deliver turnkey solutions, offering service stations, fleet operators, and bus depots tailored expertise in the design, installation, and maintenance of charging infrastructure.  

Infrastructure for e-trucks.

The rise of electric trucks presents an enormous opportunity for service stations to reinvent themselves as next-generation mobility hubs. TSG, leveraging its extensive expertise, is already working with service stations across Europe to prepare for the e-truck revolution. In the Netherlands, for instance, TSG is leading the development of the Whatthub project, a state-of-the-art e-truck charging hub tailored to meet future mobility needs. 

With a team of 6,000 skilled technicians physically based in all European countries, TSG provides end-to-end solutions – ensuring reliable, efficient, and sustainable charging infrastructure. By integrating high-power DC chargers, solar panels, and energy storage systems, TSG helps service stations offer optimal charging for heavy vehicles while reducing their carbon footprint.  

The deployment of Megawatt Charging Systems will be a game-changer for long-haul e-trucks, enabling them to recharge during mandatory rest breaks. TSG’s technicians are experts in the design and implementation of these systems, ensuring that every station is tailored to meet the specific needs of drivers. Charging stations are designed with truck drivers in mind, offering ample parking space and additional services such as rest areas, restaurants, and gyms to enhance their experience.  

In Germany, TSG is executing the large-scale Milence project at Hermsdorfer Kreuz, which serves as a prime example of the company’s expertise in large-scale e-truck charging infrastructure.  

As a true one-stop-shop, TSG not only provides installation but also offers 24/7 maintenance services, ensuring that every charging station operates smoothly and efficiently, minimizing downtime for operators and drivers alike.  

Supporting the electrification of bus depots. 

For bus operators, TSG provides fully integrated solutions that address every aspect of depot charging, from grid connections and internal power distribution to software that integrates charging operations with fleet schedules.  

TSG is carrying out Engineering, Procurement, and Construction (EPC) of e-bus infrastructure in Italy with the SETA project, which spans two major depots in Reggio Emilia and Piacenza. Additionally, TSG is constructing a new e-bus depot for TPER in Ferrara, where it will also install eight chargers and two pantographs in the main city square.  

By prioritizing energy efficiency, TSG’s systems enable bus operators to minimize costs while ensuring that their fleets are fully charged and ready for daily operations. Advanced energy management software also supports preconditioning, which optimizes vehicle performance by regulating internal temperatures before journeys begin.  

Sustainable energy integration.

TSG’s approach goes beyond charging. By incorporating renewable energy sources like solar and wind, TSG helps operators reduce dependency on the grid and lower operational costs. Battery storage systems further enhance sustainability by balancing energy demand and supply, ensuring reliability even during peak hours. Additionally, TSG provides smart energy management solutions that optimize energy usage across sites, enabling operators to maximize efficiency.  

With a deep understanding of the unique challenges faced by its clients, TSG tailors its solutions to each operator’s specific needs and circumstances. Whether it’s upgrading a service station for e-truck charging or designing a state-of-the-art e-bus depot, TSG combines technical expertise with a commitment to sustainability to deliver projects that are both innovative and practical.  

As the demand for e-trucks and e-buses will grow exponentially, operators must act now to build the infrastructure of the future. With TSG as a trusted partner, they can navigate the complexities of this transition and position themselves as leaders in the era of sustainable mobility.