Hybrid retrofit offers a practical pathway to mining fleet decarbonisation

Thiess signs an exclusive distribution agreement to be an authorised installer of FLANDERS hybrid retrofit technology for mechanical-drive haul trucks.

Decarbonisation doesn't need to wait for next generation machinery.

The mining industry is committed to reducing emissions and while we are progressing towards battery-electric fleets, most haul trucks operating today are expected to remain in service for many years.

Globally, more than 60% of operating haul trucks have not yet reached their major rebuild interval. Replacing these assets with new battery-electric trucks is neither commercially nor operationally viable for many operations.

Power infrastructure, electrical generation capacity, capital investment and fleet availability remain significant barriers to widespread electrification. The transition to zero-emission mining is underway, but the industry's incumbent fleet cannot be ignored.

Mining haul trucks are the largest consumers of diesel on most mine sites and one of the biggest contributors to operational greenhouse gas emissions. Reducing fuel consumption from these assets delivers an immediate opportunity to lower emissions while improving operating costs.

For many operations, the next major truck rebuild presents the ideal opportunity to do more than restore the asset. It presents an opportunity to hybridise it.

A practical pathway available today

Thiess has recently signed a partnership and distribution agreement to deliver FLANDERS hybrid retrofit technology for mechanical-drive haul trucks.

The partnership combines world-leading hybrid drive train technology, with Thiess' global asset maintenance capability, engineering expertise, rebuild facilities and field delivery experience.

Rather than waiting for future battery-electric fleets, hybrid retrofit technology enables operators to reduce emissions from the assets they already own.

The solution integrates FLANDERS power inversion, battery storage and intelligent control systems with existing truck platforms, creating a practical transition technology that improves both environmental and operational performance.

Progress on CAT 793D trial

Thiess and FLANDERS have reached a significant milestone in their partnership, with the retrofit of a Caterpillar 793D haul truck now underway. Following completion of the truck strip-down (pictured below), testing and chassis remediation works, installation of the hybrid system components have begun. Current works include deck fitment, drive cabinet and battery cabinet installation, ACE assembly, and integration of the hybrid cooling and drivetrain systems.

Once the hybrid retrofit is complete, asset performance and economic modelling will be validated under real operating conditions. Subject to successful trial outcomes, we will expand our hybrid retrofit fleet and demonstrate the benefits, ready to support large-scale deployment across the mining industry.

The business case for hybrid retrofit

Decarbonisation is not only important for our clients. It's equally important for Thiess.

Thiess owns one of the largest and most diverse mining fleets globally and face the same challenge as our clients - how do we reduce emissions while continuing to maximise the value and productive life of assets?

Pre-trial modelling indicates hybrid retrofit has the potential to reduce fuel consumption and greenhouse gas emissions by approximately 16%, equating to around 360 tonnes of CO₂-e emissions per truck saved each year for a 230-tonne class haul truck. The technology is also expected to improve acceleration and maximum speed, delivering productivity benefits through faster haul cycles where site conditions permit.

By reducing diesel consumption, hybrid trucks require fewer refuelling events, increasing equipment availability and extending diesel engine life through reduced operating hours.

Decarbonisation doesn’t have to cost you millions. In fact, hybridised assets increase fleet productivity and reduce operating costs, improving $/Tonne output.

Combining hybrid retrofit technology with autonomous haulage creates a powerful opportunity to further improve productivity, fuel efficiency and operational performance.

Where to start with hybridisation

Successful fleet decarbonisation begins with understanding where hybrid technology creates the greatest value.

Thiess works with clients to assess fleet age, rebuild schedules, haul profiles, production requirements and operating costs to identify the most effective hybridisation strategy.

We can help you navigate:

which trucks should be hybridised,
how hybridisation can align with a scheduled rebuild,
does it make sense to combine hybridisation with other technology upgrades such as autonomation and idle management,
what productivity and fuel savings can be achieved, and
what these benefits deliver for your project in a $/Tonne output.

For many operations, deeper haul profiles generate the greatest benefits, making financial modelling and fleet analysis critical before implementation.

Join us on the journey

The technology is ready. It's time to explore what's possible.

Hybrid retrofit systems are available for order today, intelligent idle management is already delivering measurable fuel savings, and autonomous haulage has been proven in mining operations for years. Together, these technologies are helping reshape the future of fleets.

We invite mine operators to join us on this journey. Register for our webinars to hear from Thiess and FLANDERS experts, explore the technology in greater detail, and receive the latest updates from our hybrid retrofit program as we continue accelerating the path to lower-emission mining.