Fuel cell buses: Powering Germany’s most demanding routes toward zero emissions

Germany’s transition to zero-emission public transport is accelerating. Battery electric buses (BEBs) are proven on shorter, inner-city routes, but longer, high-frequency, and geographically demanding services are the true test for full-fleet decarbonization in daily operations. Most of the easy routes have already been electrified; now, transit operators are turning their attention to the challenging ones. 

These demanding routes include longer distances (by kilometers or operating hours), peri-urban and rural lines, higher-speed services, routes with hills and steep gradients, and regions with difficult weather conditions — all year round. 

For many operators, grid-constrained depots are becoming a major bottleneck. Limited space, restricted grid access, and the high cost of infrastructure upgrades make large-scale battery charging impractical at some locations. This is where fuel cell electric buses (FCEBs), powered by hydrogen, emerge as a key enabler — offering the range, rapid refuelling, and reliable year-round performance required to decarbonize even the hardest routes without major grid investments. 

Where fuel cells make the difference 

BEBs are ideal for short, predictable city routes. On high-frequency, regional, or steep and undulating routes, bus operators face challenges such as limited charging windows, scheduling constraints, and reduced range in extreme temperatures. 

• Increasing battery pack size
• Installing opportunity chargers along routes
• Deploying additional buses
• Using diesel or HVO heaters to mitigate cold-weather impacts

FCEBs can bridge this gap, offering a 350–450 km range, refuelling in under 10 minutes, and consistent performance throughout the year. Unlike BEBs, which depend on energy-intensive charging infrastructure, hydrogen buses can operate from any depot with scalable refuelling capability — drastically reducing footprint and capital cost. 

• Data from the European JIVE and JIVE 2 programs, including German fleets in Cologne (RVK) and Wuppertal (WSW), demonstrate fuel efficiency of 6–9 kg H₂/100 km and availability of up to 95%. Drivers and passengers highlight smooth, quiet operation and dependable performance under demanding conditions — proving that hydrogen buses can match diesel performance without emissions. FCEBs have been successfully operated in both hot and cold climates without service disruption or the need for auxiliary generators. FCEBs are a true 1:1 replacement for diesel buses in a fleet, even on the most challenging routes. 

A growing ecosystem of fuel cell bus OEMs 

Across Europe, the FCEB market is expanding rapidly. Leading manufacturers, including Solaris, Wrightbus, MCV, Nesobus, Arthur Bus, and Habas, now offer production-ready hydrogen models powered by Ballard fuel cell modules. From 12-meter city buses to articulated regional and Class 1 intercity models, these vehicles are built to meet the rigorous demands of European service conditions. 

For German operators, this growing ecosystem translates into greater choice and security of supply, supported by a mature value chain for refuelling, servicing, and training. Early adopters such as RVK Cologne — with 160 buses in operation — and WSW Wuppertal have proven that hydrogen buses can sustain intensive operations in regions where battery solutions would require operational compromises. There are now nearly 500 FCEBs deployed in Germany. 

Confidence through partnership and lifecycle support 

Successful FCEB operation depends on more than vehicles — it requires strong technical partnerships and lifecycle support. Ballard powers more than 80% of FCEBs currently on the road in Europe, leveraging extensive operational experience. 

We collaborate closely with European bus operators to deliver integrated support, including digital monitoring, training, and proactive maintenance planning. This “Here for Life” partnership model maximizes uptime, simplifies daily operations, and builds confidence as fleets expand. Key elements include technical deployment, comprehensive training, monitoring and analytics, and proactive, preventative maintenance planning.

Total cost of ownership and hydrogen supply 

While capital costs and energy prices are important, operational realities — fleet availability, vehicle uptime, depot investment, staff training, and predictable maintenance — ultimately determine the Total Cost of Ownership (TCO). FCEBs reduce the need for costly grid upgrades and ensure dependable operation on challenging routes. With Ballard’s lifecycle support, operators gain transparency and predictability in both service reliability and costs. 

Hydrogen refuelling infrastructure costs and hydrogen pricing are key considerations, but fleets can scale efficiently through strategic investments and partnerships with regional hydrogen suppliers. Germany already has a mature hydrogen production and distribution ecosystem supported by both international and regional companies. As hydrogen production scales up, prices will fall — further improving TCO. 

Completing the zero-emission mix 

Battery and fuel cell buses are complementary technologies. The practical path to full fleet decarbonization is to use each where it performs best: battery buses for inner-city, low-range services, and fuel cell buses for long, hilly, and high-frequency routes. Together, they enable operators to decarbonize entire fleets faster — without compromising service. 

Supported by strong German government funding, an expanding OEM supply base, and proven operational performance, FCEBs are poised to drive the next phase of zero-emission transport — bringing hydrogen mobility to Germany’s most demanding routes.