Wrightbus’ NewPower division advances its repowering programme with EV-to-EV conversion agreement for Metroline in UK

Wrightbus’ repowering division, NewPower, is extending its scope beyond diesel-to-electric conversions with a new contract involving an existing battery-electric fleet. Metroline has selected the company to upgrade 28 Metrodecker electric double-deckers. A couple years ago a batch of Optare early generation e-buses had been updated by Equipmake by installing a new powertrain.

Bus manufacturer Wrightbus had opened the re-powering service by launching NewPower in June 2024, a new entity headquartered at the former location of EV startup Arrival. 

The vehicles involved are early-generation BEVs whose operation has been constrained by limited range and inconsistent reliability. The conversion work will be carried out at NewPower’s facility in Oxfordshire.

NewPower upgrades electric buses

The programme includes the full replacement of the main zero-emission systems. Kreisel battery packs will be removed and substituted with a CATL configuration offering higher usable energy (which sounds new, as NewPower had initially announced Forsee Power as the provider of its battery modules). The driveline, axles and powertrain will be renewed, while HVAC will shift to a Grayson unit with heat-pump heating. Propulsion will be provided by a Voith (from November 1st: Driventic) electric drive system.

Wrightbus states that more than three-quarters of component value within NewPower projects is sourced from UK suppliers. With this agreement, the repowering division reports 64 orders scheduled for delivery in 2026, exceeding the more than fifty units expected to be completed in 2025.

Wrightbus CEO Jean-Marc Gales says: “Our engineers have proved beyond doubt that they can tackle 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. 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. 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. This latest deal increases the orders for NewPower to 64 for next year, already above the 50-plus we will have delivered in 2025.”

John McLeister, Wrightbus Group MD Sales, UK and Ireland: “We are putting in gold standard equipment into these Metrodeckers to maximise performance and efficiency.”