Wrightbus’s NewPower secures landmark EV-to-EV repower deal in major boost for zero-emission transport

NewPower, the repowering division launched by Ballymena-based zero-emission bus manufacturer Wrightbus in 2024, has announced a groundbreaking EV-to-EV Repower agreement with leading operator Metroline.

The deal marks the first time NewPower will upgrade an existing electric fleet with state-of-the-art EV technology, positioning the company at the forefront of Europe’s transition to greener public transport.

Under the contract, 28 Metrodecker electric buses—previously hindered by limited range and reliability issues—will undergo a comprehensive transformation at NewPower’s cutting-edge repowering facility in Oxfordshire, the largest of its kind in Europe.

The upgrade programme will see key systems replaced with newest-generation components, significantly enhancing performance, efficiency and operational lifespan.

NewPower will replace the original Kreisel batteries with a CATL configuration that delivers 50% more power, while also installing a Grayson HVAC and heat-pump heating system alongside a Voith electric drive system. New axles, drivelines and powertrains will further modernise the double decker fleet.

Wrightbus, the first original equipment manufacturer (OEM) to offer a repowering service, has traditionally focused on converting diesel buses to electric. This new deal expands its capabilities, demonstrating the potential of updating first-generation electric vehicles with second-generation technology.

Wrightbus CEO Jean-Marc Gales said his engineers had proved “beyond doubt” that they could meet all zero-emission challenges.

“While it’s clear that ageing diesels would benefit from a switch to EV, the rapid development of battery and driveline systems in the last three years means we have the ability to update first generation electric vehicles with the latest technology and make enormous increases in power, range and efficiency,” he explained.

He added: “The new battery systems have ramped up output, increasing the range available while also making it quicker to charge. It’s a real game-changer and enables operators to upgrade their fleets without always having to buy new.”

Gales highlighted the strong UK supply chain backing the project:

“More than 75% of the component cost of a bus comes from our UK suppliers and we will continue to strengthen our ties in the face of stiff competition from overseas.”

The EV-to-EV repower deal brings confirmed NewPower orders for next year to 64, surpassing the 50-plus units due to be delivered in 2025. According to the CEO, this milestone “makes NewPower the largest repower specialist in Europe.”

Wrightbus Group MD Sales for the UK and Ireland, John McLeister, emphasised the quality of technology being deployed:

“We are putting in gold standard equipment into these Metrodeckers to maximise performance and efficiency.”

The transformation of Metroline’s Metrodecker fleet is expected to bolster the operator’s zero-emission capability while providing a cost-effective alternative to fleet replacement, underscoring the growing importance of repowering as the UK strives toward net-zero transport goals.