The Largest Fleet Retrofit Project in the World

Project summary

Zeronox and the Jospong Group have partnered to execute the world’s largest fleet retrofit electrification project, transforming 1,000 internal combustion engine (ICE) refuse trucks in Ghana into zero-emission vehicles using the proprietary Electric Powertrain Platform (ZEPP). With an initial pilot phase complete, the project is now entering mass deployment. The transformation delivers massive carbon reductions (~400,000 metric tons of CO₂ abated), ~$300 million in projected savings, and a payback period of under three years. This groundbreaking initiative highlights the viability of electrification in emerging markets and sets a model for scalable, sustainable fleet transformation in Africa and beyond.

Mass Production Specs (Post-Pilot Fleet)

What:

1,000

Class 8 Swing Arm Skip Trucks; Single Axle Compactor Trucks; Dual Axle Compactor Trucks

Route:

100

km daily driving distance for single & dual axel compactors

Route:

240

km daily driving distance for swing-arm skip trucks

Payback period:

years

Charging:

120

kW dual-gun DC EVSE. 5h for swing arm / 2.5h for compactor trucks

Annual Fuel cost savings (Million USD):

with annual maintenance savings ~$20M

CO2 Savings (metric tons):

400,000

abated from driving zero emission

Who:

600

Mechanics upskilled to EV technicians

Timeline

2021

Initial feasibility visit conducted in Ghana by Zeronox to assess electrification opportunities for Zoomlion’s waste fleet.

2022

Zeronox and Jospong formalize partnership: MOU signed, Jospong team visits California, and commercial contract executed.

2023

First pilot trucks shipped from Ghana to California for retrofitting at Zeronox’s facility, achieving successful Alpha truck retrofit.

2024

Local technician training begins in Ghana, led by Zeronox; charging infrastructure planning and strategy work conducted to enable fleet deployment.

2025

Mass production and large-scale deployment of electrified Zoomlion trucks underway following successful in-country validation.

Who Was Involved

Zeronox – The technology provider and system integrator behind ZEPP; responsible for design, retrofit, and validation.

Jospong Group – One of Ghana’s largest conglomerates; key implementation partner managing the fleet transition.

Zoomlion Ghana Ltd. – Jospong’s waste management arm; operates the electrified trucks.

Local Ghanaian Engineers & Mechanics – Participating in EV technician upskilling programs.

Curriculum Partners – Educational institution partners assisting with local training such as Porterville College and the Jospong Academy.

Lessons Learned

Design for the Duty Cycle

Electrification efforts are most successful when they focus on predictable and repetitive duty cycles, such as consistent routes. This ensures optimized battery usage and range management. The relative lower average speed of the refuse trucks along with stop-and-start operations were ideal to recapture energy through regenerative braking.

Plan Charging Infrastructure Early

Charging logistics must be embedded in fleet operations to avoid downtime. Charging infrastructure must be strategically planned and implemented to meet the fleet’s operational needs. This includes access to high-quality, reliable charging stations and potential on-site energy storage solutions.

Build Local Capacity

Transitioning from internal combustion engine (ICE) vehicles to electrified fleets requires upskilling existing mechanics into certified electric vehicle (EV) technicians. Providing specialized training for local mechanics and EV drivers are critical for safety, maintenance, and long-term success. Early buy-in from drivers, managers, and city officials accelerated adoption and reduced resistance.

Retrofits Can Scale Quickly

With pilot success, 1,000 trucks are scheduled to be electrified—demonstrating a replicable model for emerging markets.

Local Supply Chain and Support

Developing a local supply chain for spare parts and technical support reduces downtime and dependence on imports, ensuring quicker resolutions to maintenance needs.

Project summary

Mass Production Specs (Post-Pilot Fleet)

What:

Route:

Route:

Payback period:

Charging:

Annual Fuel cost savings (Million USD):

CO2 Savings (metric tons):

Who:

Timeline

2021

2022

2023

2024

2025

Who Was Involved

Lessons Learned

Design for the Duty Cycle

Plan Charging Infrastructure Early

Build Local Capacity

Retrofits Can Scale Quickly

Local Supply Chain and Support

Further Reading

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