Wrightbus’ Repower Revolution: Interview with Jean-Marc Gales, Deputy Chairman & Paul Thomas, Chief Technology Officer

Wrightbus has long been a pioneer in zero-emission public transport. From its world-first hydrogen double-decker bus to its market-leading battery-electric models, the company continues to redefine sustainable mobility.

The company is now extending its innovation from buses to trucks. Instead of starting from scratch, it is breathing new electric life into existing diesel fleets.

The company recently achieved a major milestone by repowering an 18-tonne twin-axle DAF truck with a 282kWh battery system, under its new “NewPower” division. This breakthrough offers fleet operators a faster, more affordable pathway to decarbonization through transforming diesel vehicles into fully electric ones in four weeks.

With the commercial vehicle sector under increasing pressure to cut emissions, Wrightbus’ repower solution could prove to be the bridge operators have been waiting for: one that combines cost savings, speed, and sustainability.
Repowering extends a truck’s lifespan by roughly ten years and delivers a total cost of ownership (TCO) advantage over diesel, all while avoiding the waste and cost of scrapping functional vehicles.

Backed by Wrightbus’ proven zero-emission technology – which has already clocked more than 88 million electric miles on the road – NewPower represents both a technical and environmental leap forward.
In this interview with Automotive Industries (AI), Jean-Marc Gales, Deputy Chairman of Wrightbus, and Paul Thomas, Chief Technology Officer, explain how repowering will reshape the heavy vehicle landscape, the challenges overcome by his engineering team, and how the company plans to scale its operations across Europe.

AI: How does the conversion change the decarbonization equation for fleet operators who need fast, affordable pathways off diesel?

Gales: Repowering will dramatically change the landscape for operators. The TCO is now cheaper than diesel, and with a turnaround time of just four weeks per truck, fleets can quickly transition to full EV. We wanted to remove the barriers to electric adoption in the truck sector, focusing heavily on affordability and speed. The equation has changed operators now have a viable, fast, and cost-effective route to decarbonization.

AI: NewPower’s repower solution costs roughly half that of a new EV. What commercial or financing models make this especially attractive?

Thomas: Wrightbus belongs to a group of businesses entirely focused on zero emissions, allowing us to offer full ecosystem support – from financing and maintenance to charging and depot infrastructure.

We’re also collaborating with partners who can provide access to funding for operators, ensuring budget constraints never stand in the way of going green.

AI: What were the biggest engineering challenges in adapting your bus technology to heavy trucks?

Gales: The first hurdle was fitting the batteries while maintaining correct axle loads. We also had to integrate the new powertrain with the existing electrical system of the donor vehicle.

Thomas: Around 90% of the technology is shared with our bus products, giving us a huge confidence boost.

We placed two batteries under the cab – where the diesel engine used to be – to optimize weight distribution and preserve payload.

AI: How do you measure lifecycle and TCO benefits for operators choosing between repower and buy-new?

Gales: We use in-house TCO and lifecycle GHG modeling tools, developed with W-Tech at Queen’s University Belfast. These tools, validated through our bus projects worldwide, allow data-driven decisions. Operators see a rapid four-week turnaround, clear carbon savings, and real-world TCO results that match our models closely. Extending a truck’s useful life also brings major ESG benefits.

AI: With facilities in Ballymena and Bicester, how will you scale and maintain affordability?

Thomas: We have the largest repowering capability in Europe. Between our 2,300 skilled employees in Ballymena and our advanced Bicester site, we’ll soon be able to repower around 400 trucks annually, creating roughly 160 new jobs. Ballymena will serve Ireland and Northern Ireland first, with Bicester focused on UK fleets.

AI: Finally, how does the truck program fit into Wrightbus’ global growth plans?

Gales: Our mission is clear – to help operators decarbonize and bring clean air back to our towns and cities. Moving from buses to trucks is a natural evolution. There are about 30,000 DAF trucks in the UK alone ready for repowering, and that’s just the beginning. We’re building a platform for sustainable growth – in every sense of the word.