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Fuel-cell Technology

UK companies showcase diesel-to-hydrogen conversion technology for commercial vehicles

Web TeamBy Web TeamAugust 14, 20252 Mins Read
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1. Metier and Mahle will demonstrate their hydrogen-converted diesel truck at Cenex Expo

Metier Technologies and Mahle Powertrain will demonstrate a hydrogen-powered commercial vehicle at Cenex Expo in early September, showcasing technology that converts existing diesel trucks to run entirely on hydrogen fuel.

The demonstration vehicle uses a 6.7-litre, 6-cylinder engine mounted in a DAF LF220 platform. The conversion process integrates specialised hydrogen injectors with Mahle Powertrain’s Flexible ECU engine control software platform, which provides the mapping and calibration needed for hydrogen combustion.

“This project will demonstrate what can be achieved when engineering expertise meets urgent environmental needs,” said James Budgett, Managing Director of Metier Technologies. “Working with Mahle Powertrain’s established control technology, we’ve proven that existing diesel trucks can be rapidly converted to hydrogen power, offering depot-based fleet operators a practical, commercially viable pathway to zero-emission transport without waiting for entirely new vehicle platforms.”

Mahle Powertrain’s control system manages the precise requirements of hydrogen combustion while ensuring safety standards. The company’s new heavy-duty hydrogen test bed facility in Northampton enabled engine mapping and performance testing ahead of the September exhibition.

Mike Bassett, Engineering Director at Mahle Powertrain, will present on hydrogen internal combustion engine design at the expo, including discussion of the company’s Jet Ignition technology.

The conversion technology targets commercial fleet operators seeking zero-emission alternatives that maintain operational capability for longer duty cycles and heavier payloads compared to battery electric options. Metier’s strategy focuses on regions with established hydrogen infrastructure, particularly Scotland and Southwest England, aligning with government hydrogen production commitments through 2030.

The transformation process requires integration of hydrogen injection systems, comprehensive engine remapping using Mahle’s software platform, and installation of safety systems designed for hydrogen operation.

Following the Cenex demonstration, Metier plans to begin proof-of-concept testing with selected fleets by mid-2026, with commercial deployment scheduled for early 2027. The company is developing partnerships with hydrogen suppliers, fleet operators and leasing companies to support widespread adoption.

Cenex Expo takes place September 3-4 at UTAC Millbrook in Bedfordshire. Mahle Powertrain operates as a specialist engineering services subsidiary of the Mahle Group, with technical centres in the UK, Germany and China. Metier Technologies is a UK-based company focused on hydrogen powertrain solutions for commercial vehicles.

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