With Canada’s zero-emissions plan targeting for 2035, there is a fast-growing need for sustainable transportation; hybrid conversions are emerging as a practical solution to help reach Canada’s sustainability goals. Converting internal combustion engine (ICE) vehicles into hybrid drivetrains, transforms the vehicle’s efficiency, offering many environmental, economic, and seasonal benefits. As the market for sustainable vehicles continues to flourish, many companies are producing innovative solutions, challenging the status quo. This piece highlights the benefits and trade-offs of hybrid vehicles and their growing presence in the transportation industry.  

 

Industry Leaders ​

There are many companies that are looking to switch gears and join the EV market. One such company is Edison Motors, who are currently manufacturing commercial vocation semi-trucks. Their EV conversion story, documented on their website, started with their prototype, Carl, which was a 1962 Kenworth LW 924 made in Merrit, BC. They were able to successfully convert Carl into an EV, which runs off 2 main battery packs. These packs can be charged via a diesel generator in 20 minutes, giving 2-3 hours of driving off a full charge. That translates to roughly 12L/100 km (21mpg), which is a 70% fuel mileage increase from the original 40L/100km(6mpg). This prototype showed Edison the capabilities they have towards semi-truck EV conversions, which led them to their next product, the L series. 

 

Edison’s L series currently has a lineup of 2 different trucks: the L500 and the L750. Both are heavy-duty vocational electric semi-trucks that have a similar fuel source to Carl, a diesel generator to power it’s three separate battery-powered axles. Edison wants to highlight that the diesel generator is not necessary, this can vary depending on customers’ preferences. It can be swapped out for a gasoline or propane generator, a hydrogen fuel cell, or even more batteries to make the truck completely EV. This customization adds entirely new possibilities to the meaning behind a “hybrid truck”. A flex-fuel generator that can run off E85 to charge the batteries on the go is another sustainable solution if a full EV conversion is not feasible. Flex-fuel is more popular than diesel in 7 of 10 provinces, as well as 2 of 3 territories, so this option is very realistic for most areas of Canada. Contributing to the sustainability of their trucks, Edison choses traditional truck parts found at stores such as Fort Garry or Fleet Brake, to reduce the wait time for customers. Finally, their trucks are designed to last, taking inspiration from old vocational truck models that ran for over 50 years, such as the 1969 Kenworth or the 1971 Pacific. One truck is meant to last generations.  

 

Economic Feasibility 

The economic advantages of hybrid vehicles are among the most significant benefits for the average consumer. Moreover, these benefits avoid many of the drawbacks associated with electric vehicles. The introduction of hybrid conversion technology has further increased the accessibility of these savings to a broader audience. Hybrid vehicles and conversions provide substantial savings in fuel costs, lower initial costs, and additional advantages that enhance their appeal. 

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Although hybrid vehicles cost more to run than EVs, they’re still far less costly than standard ICEs. Hybrid vehicles still have the benefits of regenerative braking, which converts up to 70% of the energy normally dissipated into heat within the brakes, into electric potential to propel the vehicle (J.C Power, 2021). This is especially relevant to city driving, where brakes are frequently used to manage distance in the busy environment. Additionally, some hybrids provide the ability to completely disengage the ICE, further reducing fuel costs and wear on the engine. Hybrid conversions maintain similar benefits, despite suffering slightly, due to the systems being less integrated. Edison Motors, a company leading innovation in the hybrid conversion space, quotes anticipated fuel savings of 30% in their hybrid trucks. If achieved, it would match the fuel savings provided by a hybrid Corolla compared to its ICE counterpart.  

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The long-term costs incorporated yearly fuel maintenance costs summed over five years. The fuel costs were calculated assuming 20,000 km driven per year, reported by Statistics Canada, in addition to an average fuel cost of $1.60/L (average cost of gasoline in Canada in 2023). The yearly maintenance costs were taken from Canadian Automobile Association (CAA) data, which provided an estimate of $1,500-$1,700 for ICE vehicles, $1,200-$1,400 for hybrids, and $700-$800 for EVs. It's worth noting that these are estimates and individual costs may vary. 

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As seen in the table above, hybrids provide noticeable cost savings over ICE vehicles in long-term costs. Based on the data above, hybrids, on average, reduce long-term costs by 31% while only having a 13% higher initial cost and still being 29% less expensive than EVs. Consequently, the savings are more accessible compared to EVs. This can largely be attributed to the vastly larger batteries needed in EVs. According to Renault Canada, the average battery size in a “classic” hybrid is 1.2 kWh, with plug-in hybrids increasing to an average of 9.8 kWh. In contrast, a Tesla Model X uses a 100-kWh battery—almost 100 times larger than the average classic hybrid’s battery. With electric vehicle batteries costing $128/kWh on a volume-weighted average basis, according to Bloomberg NEF, this leads to a significant increase in price. Moreover, the cost of a hybrid can be further reduced by converting an existing ICE vehicle. Since the initial cost of the vehicle is already covered, the only remaining expense is the conversion. The recent James Dyson Award winner REVR aims to create a conversion kit that costs a mere 3,200 US dollars. With a cost that low, the benefits of hybrid technology would be far more accessible. 

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Environmental Impact 

Hybrid conversions are an effective solution to improve the efficiency of vehicles, significantly reducing the emissions during operation. For vehicles with engines that remain functional, converting to a hybrid, instead of a full EV, can offer many of the same environmental benefits, while utilizing the full lifespan of the motor. This approach minimizes waste, making use of the existing resources and providing a sustainable transportation solution. 

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The most significant advantage of a hybrid conversion, compared to an EV conversion, is the reduced need for battery production. According to Bloomberg NEF, the average battery size for traditional EVs is around 60–100 kWh, whereas a standard non-plug-in hybrid requires only 1.2 kWh, and a plug-in hybrid averages 9.8 kWh. Stated in the Canadian National Inventory, production of a standard EV battery produces up to 2.5 tonnes of CO₂ emissions. By utilizing smaller batteries, hybrid conversions reduce the environmental impact of battery production while maintaining many of the benefits seen in standard EV conversions. 

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Hybrid conversions offer practical advantages in industries requiring transportation, utilizing many EV benefits while maintaining a longer range. Edison Motors have taken advantage of these benefits in the logging industry. Their hybrid trucks, designed for logging, integrate a diesel generator used solely for recharging batteries, allowing them to achieve up to a 70% reduction in fuel usage, reported on their website. This increase in efficiency is largely attributed to their regenerative braking system, utilizing the kinetic energy to charge the batteries that is typically wasted. 

Edison Motors’ hybrid trucks offer the extended range needed for demanding industries. By combining smaller battery packs with a generator, their design ensures vehicles can cover long distances without the need for frequent charging. This setup also reduces fuel consumption during shorter trips, making it both efficient and practical. Hybrid conversions like these provide a balanced solution, addressing the need for range while supporting environmental and operational goals. Hybrid conversions provide a sustainable balance between reducing emissions and maintaining operational efficiency. For consumers, they help preserve vehicles with functioning engines, reducing waste. Alongside EV conversions, hybrid conversions play important roles in creating sustainable transportation solutions.

 

Weather Adaptability 

Winter presents one of the biggest hurdles for EVs: reduced battery efficiency. Research from CAA has shown that the range of EVs can decrease up to 45% at temperatures below -25°C. Compounded by the internal energy required for heating the cabin, the recommended free-charge range overstates the actual range, which may result in a failure of reaching a desired location. Conversely, hybrid conversions require fewer energy-intensive systems and can be optimized for cold weather since the engine creates heat as it burns fuel, making it more reliable and sustainable. 

 

In addition to range loss, drivers in freezing conditions can experience longer charging times. At temperatures around -10°C, DC fast charging can take 20% to 50% longer than in milder conditions, reported by Statistics Canada, which has a cumulative effect - increasing the charging time for other drivers and placing a strain on current infrastructure. According to Natural Resources Canada, demand for EV charging in colder regions (including Alberta and Saskatchewan) has increased more than 25%, exacerbating the concern expressed by 44% of owners requiring SOS or roadside assistance. Moreover, many EVs use preconditioning systems to warm up the battery before charging and exposing it to the colder temperatures, adding a further 5% to 15% energy cost. 

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In light of these difficulties, hybrid drivetrains provide an appealing alternative. Retrofitting used ICE vehicles with electric drivetrains can help alleviate many of the winter-specific issues that traditional EVs face. EV conversions tend to be more adaptable to the needs of colder climates, offering better energy management for heating and reducing the strain on the battery. As such, the wait time and increasingly growing demands for changing stations can be mitigated, resulting in a redistribution of taxpayer spending, enabling the government to respond to Canada’s other critical priorities. While demand for charging infrastructure and innovation for longer-range hybrid conversions remain a critical priority, they offer an effective solution balancing the costs of greener vehicles and practicality of transportation. 

 

The Path Forward 

Hybrid vehicle conversions provide an alternative approach to sustainable transportation. This solution addresses the environmental challenges of traditional ICE vehicles, while providing many economic benefits, and addressing seasonal conditions endured by Canadians. By combining the efficiency of electric drivetrains and utilizing the extended range of existing ICE systems, hybrid conversions offer a balanced solution for many consumers and companies. Although EVs are a more sustainable solution, with the limited infrastructure in Canada, hybrid conversions may be more convenient and feasible for the average family. Overall, with companies like Edison Motors and student design teams like Queen’s Relectric Car Team, the market continues to grow with innovative solutions, providing hope for a more sustainable future.