NFI is now launching ABS batteries into bus production for customer deliveries starting in the first quarter of 2024. The Li-Ion batteries were fully designed, tested, and validated by ABS at its engineering and development center located in Lake Orion, MI. The production of these batteries will be done at ABS’manufacturing plant in Springboro, OH.

ABS operates a 120,000 sq. ft. technical center in Michigan and a dedicated 170,000 square foot State-of-the Art purpose-built battery manufacturing facility in Ohio. It employs more than 250 people in Michigan, Ohio, and Massachusetts.

ABS battery fits inside NFI existing design

NFI expects that 40% of its 2025 production will be zero-emission buses and is leading the evolution to zero-emission public transportation in North America.

The scalable custom designed pack solution purchased by NFI is based on the ABS ProLiance Intelligent Battery Series architecture and, it is stressed, “fits inside NFI’s existing battery enclosure design, providing an alternate source of supply for NFI’s battery-electric bus contracts and creating opportunity for technology enhancements”.

Design and engineering have been led from ABS’ Michigan Innovation Center in Lake Orion, with the pack production scheduled to begin in the third quarter of 2023 at ABS’ Springboro, OH manufacturing facility.

ABS says it “has secured the cell supply by partnering with world-class cell makers in strategic alliance. These partnerships have resulted in the signing of long-term supply agreements that ensure cell supply through the end of the decade, supporting the NFI ramp along with ABS’ other customer programs”.

ABS batteries for New Flyer

“We are excited and proud to partner with NFI, a company at the forefront of electric-powered public transportation. This contract reflects NFI’s well-placed confidence in ABS’ ability to meet technical and performance requirements at a healthy volume with the competitive cost position,” said Subhash Dhar, ABS Founder, Chairman & CEO. “We have invested over $ 200 million in our state-of-the-art automated pack assembly line and facility, with the capacity to deliver the product NFI needs so that it can continue to lead the electrification of public transportation in North America.”

“Demand for battery-electric buses is accelerating, and NFI is leading the evolution to zero-emission public transportation in North America. Our partnership with ABS will provide NFI with the capacity, flexibility, and resiliency we need as we ramp up production at our facilities across North America,” said Paul Soubry, President, and CEO, NFI. “ABS has made significant investments in their pack assembly and battery technology, providing NFI with industry leading solutions. We look forward to working together with ABS to advance battery technology within the public transportation industry.”

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The purchase includes forty-eight 40 ft. buses and nine 60 ft. articulated buses. Buses are scheduled for rollout starting in late 2024 with most of them being deployed in the Watsonville service area. This move will enable METRO to fully serve Watsonville and Santa Cruz County with zero-emissions vehicles.

Santa Cruz METRO aims to be 100% emissions-free by 2037.

Fuel cell buses in place of CNG and diesel buses

These buses will be replacing the existing aging compressed natural gas (CNG) and diesel buses. Currently, METRO’s fleet is comprised of only 10% zero-emissions buses (ZEBs), but with this purchase, that number will be over 69%, the operator states.

This transition will help METRO achieve 100% zero-emission technology ahead of California’s Innovative Clean Transit (ICT) Regulation deadline.

In conjunction with the FCEB procurement, METRO plans to construct a hydrogen fueling station to support the transition of their entire 94-bus fleet to zero-emissions vehicles. The station will also have the capacity to facilitate the fueling needs of local partner agencies and others.

To finance this initiative, METRO says it has secured $20.4 million in grant funding from the Federal Transit Administration and a $38.6 million award from the California State Transportation Agency’s Transit and Intercity Rail Capital Program. Additionally, METRO has applied for an additional $27 million from the California Air Resources Board’s Volkswagen Environmental Mitigation Trust.

In June, METRO committed to purchasing the FCEBs from North American bus manufacturer New Flyer, and in August, the California Transportation Commission approved the use of 2023 TIRCP award funds for this purpose.

This decision to purchase FCEB’s emphasizes METRO’s dedication to environmental stewardship and a sustainable future. If you would like to support the Santa Cruz Metro and protect Monterey Bay’s extraordinary natural resources, you can do so just by simply riding the bus via the One Ride at a Time (ORAT) program.

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Winnipeg gets zero emission buses from New Flyer

The new five-year contract includes the following firm orders: four Xcelsior CHARGE FC fuel cell-electric 40-foot, heavy-duty transit buses and four Xcelsior CHARGE FC fuel cell-electric 60-foot transit buses (8 EUs). In addition four Xcelsior CHARGE NG battery-electric 40-foot transit buses and four Xcelsior CHARGE NG battery-electric 60-foot transit buses are being procured.

Through this purchase of ZEBs, Winnipeg Transit accelerates its transition to a 100% zero-emission fleet ahead of the 2050 target outlined in Winnipeg’s Climate Action Plan, delivering on a promise to realize the city’s sustainable future vision. Funded through the Investing in Canada Infrastructure Program, the high-performance ZEBs will be built on New Flyer’s proven Xcelsior platform.

“We’re proud to extend our partnership with NFI to modernize our transit fleet and move toward zero emissions,” said Mayor Scott Gillingham. “This purchase will also support local jobs and build Winnipeg’s reputation as a centre of excellence for transit manufacturing and sustainable transit technology.”

“NFI has led innovation in North American public transit for decades, and today we stand ready with our next generation zero-emission buses to help communities transition to no-emission mobility,” said Chris Stoddart, President, North American Bus and Coach, NFI. “NFI’s partnership with Winnipeg Transit spans 35 years, and we have delivered more than 1,560 transit buses to Winnipeg Transit since 1987. We are now proudly enabling the agency’s transition to a low-carbon future through our efficient, long-range battery-electric and hydrogen fuel cell-electric buses for healthier Manitoba communities.”

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The firm orders include 28 Xcelsior compressed natural gas forty-foot, heavy-duty transit buses, and 13 Xcelsior CHARGE NG battery-electric forty-foot, heavy-duty transit buses.

The five-year contract includes options to purchase forty-foot and sixty-foot Xcelsior CNG buses, as well as forty-foot and sixty-foot Xcelsior CHARGE NG battery-electric buses.

FTA fundings for up to 432 New Flyer buses in San Diego

Supported by FTA funds, this order will help MTS meet its goal of transitioning to a zero-emission fleet, which is outlined in its multi-year “Zero-Emission Bus Rollout Plan”. In addition, the purchase will deliver on the California Air Resources Board’s (“CARB”) Innovative Clean Transit regulation, requiring agencies to transition to 100% ZEB fleets by 2040.

Launched in early 2021, New Flyer Xcelsior CHARGE NG sixty-foot and forty-foot buses (18 and 12-meter) feature up to 763kWh and 654kWh of power. The model “incorporates three distinct technology advancements, including high-energy batteries, advanced protective battery packaging for easy install and simpler serviceability, and a new lightweight electric traction drive system with up to 90% energy recovery”, New Flyer stresses.

MTS is one of the oldest transit systems in Southern California, serving the San Diego community for more than 135 years. MTS operates one of the cleanest public transit fleets in the United States, New Flyer says, providing 88 million annual passenger rides across San Diego County on nearly 100 fixed bus routes.

MTS San Diego towards zero emission bus fleet by 2040

“MTS and NFI have had a great working relationship for many years, and we look forward to continuing it with this new contract,” said Sharon Cooney, MTS chief executive officer. “To meet the demands of transitioning to all zero-emission bus fleet by 2040 we will need NFI to step up in a big way. As they continue to improve bus zero-emission technology and performance, I’m confident our transition will be successful.”

“The electrification of mass mobility is gaining momentum now, and NFI stands at the forefront of this evolution with its market-leading sustainable mobility solutions,” said Chris Stoddart, President, North American Bus and Coach, NFI. “Through a partnership spanning nearly 30 years, NFI has delivered over 840 buses and coaches to MTS, and we are excited to continue working together as we support MTS’ transition to cleaner, more sustainable mobility with our high-performance low- and zero-emission buses. Together, we’re building healthier and more livable communities across San Diego.”

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In September 2022 New Flyer unveiled its next generation fuel cell bus model Xcelsior CHARGE FC, with fuel cell module from Ballard Power Systems and Siemens ELFA 3 at the driveline. 

New Flyer named partner for over $380 million in grants

New Flyer supported the successful applications for over $380 million in grants awarded to 38 U.S. public transit agencies and was the named partner for two individual agency awards of over $25 million each. This was an increase from the $40 million in Low-No grants awarded to nine U.S. public transit agencies that NFI subsidiaries supported in 2021.

While New Flyer has been named as a partner, new awards will not be added to NFI’s backlog until contract documentation is completed and a formal purchase order is received. New Flyer’s success with Low-No and Buses and Bus Facilities grants provide future backlog growth opportunities, the manufacturer points out.

FTA grants for procurement of zero emission buses

Grant funds support the procurement of ZEBs and the associated charging infrastructure from New Flyer. In addition to those awards where New Flyer is a named partner, almost $800 million of Low-No and Buses and Bus Facilities awards were made to other U.S. public transit agencies that have not yet to select a specific provider. The Company expects these awards to create future bidding opportunities for NFI’s businesses as unique programs are released by agencies, still New Flyer says.

“NFI is proud that subsidiary New Flyer has been selected as the partner of choice for numerous public transit agencies as they look to reduce emissions in their cities through these FTA grant programs” said Chris Stoddart, President, North American Bus and Coach, NFI. “Our success demonstrates NFI’s leadership in low- and zero-emission buses, including our wide range of battery- and fuel cell-electric products and our Infrastructure Solutions offering charging. The growth in these FTA grant programs, from $182 million in 2021 to over $1.6 billion of funding in 2022, is a testament to the strong tailwind of public support that will inevitably transform America into an electric bus future. NFI looks forward to continuing to lead the evolution to zero-emission mobility— what we call the ZEvolution.”

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California’s GET in late 2021 has ordered 5 fuel cell buses by New Flyer.  This order follows a prior (2020) GET bus purchase of five forty-foot fuel cell-electric Xcelsior CHARGE H2 buses. Still il California, New Flyer hydrogen buses have been ordered also by Orange County Transportation Authority (OCTA) and San Francisco Bay Area’s AC Transit.

It uses hydrogen and fuel-cell technology to create electricity and to charge batteries for zero-emission extended-range, saving 85-175 tons of greenhouse gas per year from tailpipe emissions compared to a traditional diesel bus. With a stated range of over 370 miles. The bus can be refueled in 6-20 minutes depending on the model and operating conditions and requires no overnight plug-in electrical re-charging, New Flyer stresses.

New Flyer Xcelsior CHARGE FC unveiled

The bus is built on the Xcelsior platform with over 16,000 buses delivered to date, New Flyer’s battery-electric and fuel cell-electric models have surpassed over 15 million electric vehicle service miles.

The battery packaging, developed by New Flyer, utilizes a waterproof enclosure design that is lighter and easier to maintain, decreasing the number of parts by 90%. What is interesting, still as presented by New Flyer, “streamlined design enables technicians to simply “plug in” or “unplug” individual battery packs, significantly reducing bus downtime and allowing easy replacement”.

New Flyer manufactures its energy storage system enclosures in its bus production facilities. The battery packaging, developed by New Flyer, utilizes a waterproof enclosure design that is lighter and easier to maintain, decreasing the number of parts by 90%. Its streamlined design enables technicians to simply “plug in” or “unplug” individual battery packs, significantly reducing bus downtime and allowing easy replacement.

New Flyer partners with Ballard and Siemens

The new FCmove-HD+ fuel cell power module from Ballard Power Systems introduces a more compact and robust design with lifecycle cost reductions achieved through lower maintenance requirements, higher reliability, and fewer parts. The integrated design houses all subcomponents in a single enclosure; it is smaller, lighter, and uses 50% fewer parts, making it easier to service and maintain. It offers over 97% fuel cell power availability while in service, and a wider operating range across a variety of climates, New Flyer states.

Finally, manufacturer says that the Siemens ELFA 3 traction system delivers up to 90% energy recovery through regenerative braking and weighs 69% less than ELFA 2, delivering a more efficient design through compact inverters and embedded drive controllers. 

New Flyer’s Xcelsior CHARGE FC, manufacturer says, “incorporates four distinct technology advancements to deliver a robust, long-range, high-performance hydrogen fuel cell-electric bus, including a lighter, simpler, and more efficient heavy-duty fuel cell power module that is easier to service; recyclable, high-power batteries delivering a longer range of over 370 of miles of highway driving without refueling; a redesigned waterproof (IP 67 and IP 69 rated) battery enclosure providing improved serviceability; and a high-grade, electric drive traction system with up to 90% energy recovery”.

Fuel cell buses for the new mobility era

“The Xcelsior CHARGE FC includes the latest technology innovations. The new streamlined design is easier to service and maintain, delivers longer range at highway speeds, improves energy recovery, and is smart city-capable, making it the most advanced hydrogen fuel cell-electric bus available on the market,” said Chris Stoddart, President, North American Bus and Coach, NFI. “With the Xcelsior CHARGE FC now added to NFI’s market-leading EV and AV vehicle lineup, NFI is undeniably leading a new mobility era, delivering unmatched performance and sustainability benefits to transit operators.”

“More and more cities are making the commitment to 100% zero-emission fleets and Xcelsior CHARGE FC provides an ideal complement to battery-electric buses for agencies wanting to integrate the reliable long-range performance of hydrogen fuel cell-electric buses,” said Jennifer McNeill, Vice President of Public Sector Sales and Marketing, New Flyer and MCI. “The Xcelsior CHARGE FC also advances our effort to continue driving the adoption of zero-emission mobility with a safe, scalable, and streamlined approach to the zero-emission manufacturing process. In turn, we simplify training for our production teams and those of transit agencies across North America to continue supporting reskilling, upskilling, and workforce development to ensure successful zero-emission deployments.” 

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These buses are expected to begin service in 2023.

California, SamTrans orders 30 zero emission buses

SamTrans will be introducing a mix of BEB and FCEB at the launch of its Zero Emission Bus (ZEB) fleet deployment to assess how the two technologies perform under different conditions, which can serve which routes better and what it would require to meet their infrastructure needs. Ultimately, SamTrans announces it will develop a plan for full ZEB conversion of the fleet by 2034, six years before the state mandated conversion in 2040.

The purchases award a $13.9 million contract with New Flyer of America for the FCEBs and a $22.8 million contract with Gillig for the BEBs. It is fully funded by a combination of federal, State and SamTrans sales tax funds. The new buses will replace the 2009 40-foot diesel buses, some of the oldest vehicles in the SamTrans fleet. The diesel buses have reached the end of their useful life and are due for replacement to ensure continued reliable service for passengers and compliance with Federal Transit Administration (FTA) and Metropolitan Transportation Commission (MTC) guidelines.

The new 40-foot buses will be used throughout SamTrans service area and can carry approximately 38 seated passengers with up to another 18 riders standing, the operator outlines.  Like all SamTrans buses, the new buses have priority seating for seniors and people with disabilities and exterior bike racks that can accommodate up to three bikes.

Still SamTrams adds that the new buses will have USB charging ports on all double seats. The buses will have disc brakes, which are becoming an industry standard as they require less maintenance and upkeep. The buses have a low-floor design, which will mean that the buses will be equipped with ramps rather than lifts, and Q-Pod wheelchair restraint systems to secure wheelchair users that are easier for operators and include additional safety features beyond the existing ratchet-based system.

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Already in 2018 COTA announced it was working to build a decarbonized bus fleet, after having stopped in 2012 to buy diesel buses, replaced with CNG vehicles.

New electric buses for COTA, Ohio

Supported by Federal Transit Administration funds, the order expands COTA’s zero-emission fleet to ten New Flyer electric buses and delivers on the agency’s five-year Strategic Plan to improve customer experience and COTA’s sustainability goal to be diesel-free by 2025, New Flyer points out.

Introduced in 2021, the Xcelsior CHARGE NG bus “incorporates three distinct technology advancements, including high-energy batteries that extend range up to 13%, advanced protective battery packaging for easy install and simpler serviceability, and a new lightweight electric traction drive system with up to 90% energy recovery”, New Flyer stresses. 

COTA provides public transit in the greater Columbus and central Ohio region, delivering more than 19 million passenger trips in 2019. In 2020, COTA received its second Outstanding Public Transportation System Achievement Award from the American Public Transportation Association. 

“Since 2001, NFI has delivered over 165 transit buses to COTA. We are now are enabling its transition to zero-emission with high performance buses and infrastructure,” said Chris Stoddart, President, North American Bus and Coach. “Our Xcelsior CHARGE NG is our most advanced EV featuring a lightweight traction system, offering extended range, and incorporating up to 525kWh of power. Our mobility solutions are truly leading the “ZEvolution” – and COTA is at the forefront of North America’s transition.” 

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In 2018 the same TTC Toronto received 55 hybrid buses from Volvo’s company Nova Bus. New Flyer has already been delivering e-buses in the city. In September 2020 TTC had 35 e-buses in operation, with 25 to come as a result of a 60-units electric bus tender.

All 202 of the buses will be equipped with BAE Systems’ next-generation Modular Accessory Power System. The buses are also configured with intelligent geo-fencing technology, that through GPS navigation, will turn off the diesel engine and operate in zero-emission electric mode when entering designated areas. 

New Flyer hybrid buses for TTC Toronto

TTC is the third-largest transit system in North America, delivering more than 526 million annual passenger trips through its bus, subway, streetcar, and paratransit services in Toronto, Ontario. TTC currently operates the largest fleet of battery-electric buses in North America. 

The buses modernize TTC’s fleet and propel the agency’s 5-Year Service Plan and 10-Year Outlook, designed to meet the growing demand for transportation in Toronto.

In addition to the awards received and added to backlog, NFI group says that «the forty-foot hybrid-electric heavy-duty transit bus contract also includes 600 options made available to other Ontario-based transit agencies. Agencies can use these additional options to make their own hybrid electric bus purchases, often in a more expedited manner than traditional procurements. As there are no defined quantities allocated to NFI, or any other original equipment manufacturer, from these additional options they are not included in backlog, and will be once a customer purchases a bus under the agreement». 

“NFI’s leadership in hybrid-electric mobility spans 20 years, supplying more hybrid buses in North America than any other manufacturer,” said Chris Stoddart, President, North American Bus and Coach. “Our partnership with TTC started 55 years ago. Since 1968, we have delivered nearly 1,000 vehicles, including 25 battery-electric buses – making New Flyer the only provider of both hybrid-electric and battery-electric buses to TTC. With these new buses, NFI adds the ability to meet green zone regulations through intermittent zero-emission operation, and ultimately, is helping accelerate TTC’s transition to zero-emission and building a more livable GTA.” 

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ABB claims its charging solution for St. Louis «represents the largest deployment of chargers in the U.S. for a transit authority». ABB will provide 23 chargers e-bus Buy America-compliant chargers, with over 4,350 kW (4.35 MW) of charging capacity for this project. The system consists of 20 plug-in depot chargers with 150 kW of power and three additional pantograph chargers.

ABB powers New Flyer electric buses in St. Louis

This collaboration between Metro Transit, New Flyer and local, state, and federal governments are expected to save 100 to 160 tons of carbon-polluting emissions every year and up to $125,000 in maintenance savings and up to $400,000 in fuel savings over the 12-year lifespan, ABB points out in a press note.

“We are proud to have a role in this big shift to cleaner transportation for the city of St. Louis. The adoption of electric buses is where large cities can make a meaningful impact,” says Bob Stojanovic, Senior Vice President of ABB E-mobility, North America “Our mission is to ensure that our EV charging solutions contribute to a zero-emission future. We are confident that the deployment of our intelligent technologies will reduce operational costs, inspire increasing electric bus adoption in a safe, smart and sustainable way,” adds Stojanovic.

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