Grayson reaches 1,000+ electric buses under maintenance contract (almost 25% of HVAC servicing portfolio)

Grayson Thermal Systems has announced that its Aftermarket division now supports more than 1,000 electric buses under maintenance contracts in the United Kingdom. Electric vehicles account for around 23% of the total HVAC servicing portfolio.

According to a press note by Grayson, the Birmingham-based company is currently delivering servicing and maintenance for over 1,050 battery-electric and fuel cell buses in operation across the UK. All vehicles are equipped with HVAC systems designed and manufactured by the company.

Expansion of aftermarket services for electric fleets

This milestone reflects the evolution of Grayson’s aftermarket activities, which have expanded from diesel and hybrid vehicles to include zero-emission fleets. The company reports investments in specialist tooling, technician training and EV-specific procedures to manage high-voltage thermal systems.

The services provided include scheduled maintenance, diagnostics and system optimisation for electric and hydrogen-powered buses operating under different duty cycles and environmental conditions, as stated in the press note by Grayson.

Portfolio composition and system-level approach

Grayson reports that it currently maintains approximately 4,500 buses and coaches nationwide under contract.

Alongside aftermarket operations, the company continues to design and manufacture HVAC and thermal management systems for bus platforms. The press note by Grayson highlights that maintenance considerations are integrated at the design stage, with system layouts developed to facilitate access and servicing in operational environments.

Leanne Shenton-Smith, Head of Aftermarket for Grayson, commented: “We are proud that many major operators have entrusted us to service and maintain their electric vehicles, and reaching over 1,000 EVs under contract reflects both that trust and the pace of change across the UK bus sector. It is encouraging to see operators taking a proactive approach to maintaining the performance and longevity of their fleets through regular servicing of thermal management and HVAC systems. As is often the case, prevention is better than cure – particularly with electric vehicles, where these systems have a direct impact on efficiency, range and reliability. Unlike diesel vehicles, poorly maintained systems can reduce range and place strain on temperature-sensitive components such as batteries, while even minor issues like blocked filters can increase energy consumption and lead to avoidable downtime. At the same time, these systems are critical to maintaining a comfortable environment for drivers and passengers in all climates. As fleets continue to evolve, operators’ commitment to zero-emission transport is clear, and this milestone highlights the important role UK engineering plays in supporting that transition. By working closely with operators, we help minimise preventable issues, reduce downtime and maximise total cost of ownership.”