Turkish cement company Nuh Çimento converts its old mining trucks into electric vehicles
Purchasing new machinery is not always the most cost-effective option for renewing a fleet of industrial vehicles. A Turkish cement company has made the strategic decision to extend the service life of its large diesel-powered mining trucks—a move that represents a significant innovation in its business model. Instead of retiring the trucks and replacing them with new models, the company is converting them into fully electric vehicles, resulting in an investment saving of approximately $500,000 per unit.
This initiative was developed by Nuh Çimento in collaboration with the technology group ABB. According to documentation presented in 2026 via Business Action Bank, the conversion of each truck requires an investment of approximately $750,000. However, compared to the cost of purchasing new equipment, the company estimates that it avoids an additional expenditure of $500,000 per vehicle, while also reducing ongoing operating costs.
The conversion process involves replacing the original diesel engine and transmission with a battery-powered electric propulsion system. In this way, the vehicle retains its chassis, structure, and most of its original components, while eliminating the need for diesel fuel. One of the first models used to demonstrate the viability of this solution was a Euclid R85B—a massive dump truck that had already been in service for approximately 30 years.
Electric trucks that recover energy while in operation.
The project began in 2020, with a formal partnership with ABB established in 2022. A year later, the first prototype—dubbed "Mission Zero"—entered service. In May 2024, the two companies publicly released the preliminary results of the conversion project. Since then, the initiative has progressively expanded, accumulating data on the performance of this machinery under real-world operating conditions.
One of its most notable features relates to its strategic location in Kocaeli-Körfez, near Istanbul. The trucks transport large quantities of material downhill, navigating gradients that reach between 18% and 20%. During these descents, a regenerative braking system recovers energy that would otherwise be wasted, storing it in batteries for later use.
Once the material has been unloaded, the vehicle must return uphill, but it does so carrying significantly less weight. According to ABB, this allows the truck to complete the ascent using the electricity recovered during the previous descent. The latest project documentation indicates that this functionality extends the intervals between external recharges to between one and three months, given the specific conditions of this operation.
To achieve this, ABB developed a solution that includes its BORDLINE CC200 conversion system, a traction battery, an air-cooled electric motor, and various electronic components to manage the vehicle. The system incorporates thermal management for the batteries and fast DC charging equipment, enabling the repurposing of machinery originally designed to operate with combustion engines.
More than 240,000 liters of diesel saved with a single truck.
The results obtained confirm the cost-effectiveness of extending the service life of these vehicles. According to project documentation, the first electric dump truck had logged 5,535 operating hours by December 2025, avoiding the consumption of approximately 243,540 liters of diesel. When the conversion was announced in 2024, ABB estimated annual savings of approximately 100,000 liters of fuel and a reduction of 245 tonnes of CO2.
This experience has led to the expansion of the project to other industrial vehicles. Data published in 2026 detail the conversion of five mining trucks and twelve excavators and shovels, supplemented by another 19 electric vehicles acquired as new units. In total, the electrification program now comprises 36 heavy-duty electric machines, which have accumulated over 100,000 operating hours.
The economic impact extends beyond fuel savings alone. The company highlights a reduction in maintenance requirements, particularly following the removal of components such as the diesel engine and conventional transmission. Calculations indicate potential savings of $250,000 on engine-related maintenance over a five-year period, with an additional $150,000 in savings related to the transmission. It should be noted, however, that this conversion process also necessitates new investments in batteries, electrical infrastructure, and specialized personnel.
The company has set a goal to eliminate direct emissions associated with the transport of raw materials at its operations by 2030. It is worth noting, however, that the success of this solution depends significantly on the characteristics of the haul route, as steep downhill gradients allow for a substantial recovery of energy. Experience has shown that the electrification of heavy machinery does not always require the acquisition of new vehicles; however, it cannot be assumed that just any diesel truck can be converted with the same economic and energy-related outcomes.
