The Future of Regional Trucking: Are Electric Semis the Right Fit?

As the trucking industry transitions toward sustainability, the conversation often revolves around electric vehicles (EVs). While long-haul trucks with sleeper cabs dominate public perception, this discussion focuses on regional day cab vehicles—trucks designed for warehouse-to-delivery operations within a 200-1,000 mile range. This sector represents a significant share of trucking loads today and raises important questions about cost-effectiveness, operational efficiency, and the path forward.

Why Focus on Regional Hauling?

Regional hauling is uniquely suited for the transition to electric due to its operational characteristics. Trucks in this category typically return to a central base daily, allowing for overnight charging. Furthermore, many regional hauls cover distances well within the current range of battery electric vehicles (BEVs), often under 200 miles per trip. 

The Economics of Electrification

One of the most compelling arguments for adopting electric semis is the potential cost savings:

  1. Fuel Savings: Electricity for charging is generally cheaper than diesel, offering significant savings.
  2. Maintenance: Electric trucks, with fewer moving parts, promise lower maintenance costs compared to their diesel counterparts.
  3. Durability: Early data suggests that electric trucks could potentially last a million miles over seven years if managed well.

However, challenges remain, particularly in upfront costs, infrastructure demands, and uncertainties about long-term durability.

Real-World Testing: Data from Run on Less Electric Events

The North American Council for Freight Efficiency (NACFE) and RMI have conducted the “Run on Less Electric Depot” initiative to collect real-world data on zero-emission trucks, including models like the Daimler eCascadia, Nikola Tre, and Tesla Semi. These tests explore range, charging times, and performance in varied conditions, such as extreme weather.

Key Findings

  • Regional Feasibility: About 50% of the regional haul market—nearly 468,000 tractors—could transition to electric today.
  • Charging Infrastructure: Most charging will occur at warehouses or depots overnight, but scaling infrastructure remains a hurdle.
  • Load Efficiency: While electric trucks weigh more due to batteries, many regional hauls do not fully utilize their load capacity. Statistics show that only 57% of truck capacity is used on average, meaning the weight penalty may be less impactful in practice.

Addressing Range and Weight Concerns

A frequent critique of electric trucks is their range and weight. The Tesla Semi, for example, offers ranges between 250-500 miles per charge. Real-world tests have shown that with efficient planning, these trucks can achieve multiple short hauls in a day.

Moreover, regulations allow electric trucks an additional 2,000 lbs. of gross vehicle weight to offset battery weight. While this doesn’t fully cover the added weight, many regional hauls operate under capacity, making the adjustment less critical.

Electric Semi-Trucks: Real-World Performance Insights from an 18-Day Trial

This real-world event showcased the performance metrics of Tesla Semi, Freightliner eCascadia, and Nikola Tre models.

Here’s an in-depth analysis of their performance, charging capabilities, and implications for the trucking industry.

Tesla Semi: Leading the Charge

The Tesla Semi has made waves, with PepsiCo using the vehicle for real-world tests. During NACFE’s 2023 event, a Tesla Semi traveled 1,076 miles in a single day, showcasing its potential for high efficiency in regional routes. While Tesla’s production is currently limited, plans to scale to 50,000 units annually signal a commitment to capturing a significant share of the Class 8 market.

Key highlights include:

  • Mileage: The three Tesla Semis averaged 511 miles per day, with peak performances reaching 1,000 miles in a single day. Over the 18 days, they accumulated nearly 28,000 miles while carrying loads over 85% capacity.
  • Charging Efficiency: Tesla’s vehicles charged from 10% to nearly 100% in about two hours, showcasing the potential of V3 charging infrastructure. Future upgrades to V4 megawatt charging could further enhance these times.
  • Battery Capacity: With a 900 kWh battery, the Tesla Semi supports a 500-mile range, making it suitable for long-haul routes.

Freightliner eCascadia: Reliable but Slower

Freightliner’s eCascadia, a day cab designed for shorter routes, performed adequately but lagged in certain areas:

  • Mileage: Averaged 244 miles daily, with potential to reach 500 miles if fully utilized. However, significant downtime reduced operational efficiency.
  • Charging Time: The eCascadia required approximately four hours to charge from 11% to full capacity, doubling the Tesla Semi’s charging duration.
  • Battery Capacity: At 290 kWh, its battery size is considerably smaller, limiting its range to around 300 miles.

Nikola Tre: A Solid Contender

The Nikola Tre offered competitive performance, positioning itself as a viable alternative to Tesla:

  • Battery Capacity: A robust 753 kWh battery supports a range of 300-400 miles.
  • Charging Time: Comparable to Tesla, requiring around two hours for a full charge.
  • Mileage Potential: With consistent utilization, it could rival the Tesla Semi in daily mileage.

Comparative Analysis

Metric

Tesla Semi

Freightliner eCascadia

Nikola Tre

Battery Capacity (kWh)

900

290

753

Range (miles)

500

300

300-400

Charging Time (to 100%)

2 hours

4 hours

2+ hours

Cost (Estimated)

$200,000-$250,000

$300,000-$500,000

Similar to Tesla

Infrastructure Challenges

While the trial underscores the readiness of electric semis for operational use, several challenges remain:

  1. Charging Infrastructure: Fleets require reliable on-site charging at warehouses and distribution centers. Pepsi, for instance, collaborated with Tesla to install solar-powered chargers.
  2. Charging Times: Reducing charging durations is critical for maximizing fleet efficiency. Advanced technologies like V4 megawatt chargers promise significant improvements.
  3. Fleet Utilization: Minimizing downtime is key. The Tesla Semi demonstrated high utilization, while the eCascadia’s frequent idle periods highlighted the importance of operational planning.

Barriers to Full Adoption

Despite the promise of electric trucks, several challenges remain:

  1. Production Scalability: Current production volumes of electric trucks, including the Tesla Semi, are relatively low.
  2. Charging Infrastructure: Building sufficient charging stations at depots and along routes requires substantial investment.
  3. Battery Weight: The trade-off between battery weight and payload capacity still needs optimization.
  4. Energy Supply: Large fleets, like PepsiCo’s, need robust on-site energy generation or reliable access to charging infrastructure.

Looking Ahead

The path to electrification in regional trucking is promising but requires a balance of innovation, investment, and strategic deployment. While the technology is not yet a one-size-fits-all solution, early adopters are proving that electric trucks can succeed in specific scenarios.

As fleets evaluate their operations, they must answer critical questions:

  • How will electrification align with their business model?
  • Can they leverage available infrastructure effectively?
  • How will they manage upfront costs versus long-term savings?

The trucking industry is on the brink of transformation, and regional hauling may be the proving ground for electric semis. By addressing challenges head-on, this sector could lead the way in building a more sustainable future for transportation.

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