Australian EVS is providing a innovate pathway for mining companies to embrace electrification.
Founded by Edwin Higginson, a fleet industry veteran with experience managing national commercial fleets for companies such as Woolworths, Qube Ports & Bulk and McColl’s Transport, Australian EVS was born from the practical frustrations and opportunities of the industry itself.
“All my background has been in managing commercial fleets,” Higginson told Mining. “Then, about seven years ago, we started our consulting business to assist major fleets in a range of services, and more and more we were getting asked how to practically transition to zero emissions over the next 10 to 20 years.
“From our fleet experience, we knew it wasn’t as simple as just buying new electric vehicles (EVs), but there would need to be a range of solutions for commercial fleets and specialist equipment, from EV infrastructure, training, workshops, compliance, EV modifications and custom electric drive solutions.”
Higginson also realised the market lacked a specialist solution for repowering existing fleet assets – particularly expensive or customised vehicles that can’t simply be replaced off the shelf.
“There were huge gaps, especially when it came to practical fleet applications,” he said. “That’s where Australian EVS came in. We focused on real-world engineering to convert existing and specialist vehicles, helping fleets overcome technical hurdles and plan for the future.”
Retrofitting the future
At the core of Australian EVS’ offering are its modular ‘e-Kit’ electric conversion systems. These drop-in kits are designed to replace diesel and petrol powertrains mid-life – providing a compelling alternative to traditional engine rebuilds.
“In Australia, on average, the total age of a car is 21 years, but for commercial vehicles it can be 30 years or more,” Higginson said. “These vehicles usually have one or two engine rebuilds during their lifetime, which means we can offer an electric conversion instead of another diesel overhaul.”
This approach provides three key benefits: improving performance, reducing operating costs and drastically lowering emissions.
Australian EVS has found particular interest in sectors like mining and heavy industry, where custom modifications and harsh environments can render off-the-shelf EVs impractical.
One kit, many applications
The e-Kit platform is scalable and flexible. The e-Kit 4 is suited to classic car conversions and small machines but Australian EVS’ main focus is commercial vehicles.
“The e-Kit 6 is what we use in standard utes and vans,” Higginson said. “Then we go up to the e-Kit 8 for higher performance, and even larger systems for buses and semi-trailers.”
The conversion e-Kits are not only about replacing diesel, but customers can also specify the required range, power output, charging needs, and advanced features like regenerative braking or vehicle-to-grid integration.
All components are bench-tested in Australian EVS’ facility before being sent to customers, often with installation support for mechanics and workshops.
As a showpiece, Australian EVS converted a brand-new dual cab Toyota LandCruiser 79 Series – a cult vehicle in Australia’s harshest conditions.
“The electric version has three times more power than the original V8 diesel,” Higginson said. “It retains its high/low range 4×4 system, 3.5-tonne towing and one-tonne payload, but can now do 0–100km/hr in six seconds, has a 600-kilometre range, fast-charging capabilities, and costs a fraction of the price to run.”
It also comes at a perfect time, with Toyota recently ceasing production of the highly regarded V8 powertrain.
The business case for EV conversion
Despite the upfront costs being slightly higher than a diesel rebuild, Higginson said the long-term savings of an electric conversion are substantial.
“Our commercial fleet conversions are equivalent to a diesel over roughly 150,000 kilometres on a whole-of-life cost basis, and even quicker when using solar power. You will also reduce your emissions by 58 tonnes of carbon per vehicle over this distance when using the grid.
There are additional benefits when operating an electric vehicle, such as instant torque, lower maintenance, regenerative braking, mobile battery storage for vehicle-to-load and vehicle-to-grid, quieter operations and zero emissions.
Built for Australian conditions
One of the key differentiators for Australian EVS is its understanding of Australian conditions and what it takes to operate in harsh conditions, especially in mining.
“We use brand-new components and engineer everything in-house,” Higginson said. “When we receive a bespoke build, we use 3D scanning technology to custom design how each component and battery box will be installed into the vehicle using the vehicle’s existing mounting points.
The finished product takes up about the same space and weight as the original diesel setup. We can then add a wide range of options depending on the customer’s requirements, and additional batteries for longer range if needed, with the largest request we’ve seen being over 1000km for a WA client.
“Overseas manufacturers just don’t understand what we deal with in remote Australian regions, especially with our extreme temperatures, and how tough the equipment needs to be to operate in mines here,” Higginson said.
“Our conversions mean that 90 per cent of a client’s vehicle remains the same as the rest of their fleet and with our support, they can be maintained by an on-site workshop.”
Demand from industry
Interest in Australian EVS’ e-Kits has grown rapidly, with mining and other industries under increasing pressure to reduce costs and hit emissions targets.
“We believe that moving to electric drive solutions should first of all improve performance and reduce operating costs, with the reduction in emissions being an added bonus.” Higginson said.
Fleet operators are drawn to Australian EVS’ flexibility and engineering expertise.
“Some of the projects we’re currently working on include a modern Nissan Patrol conversion for a farmer who lives off-grid, a bus conversion, and some mine-spec LandCruisers,” Higginson said.
“We are also working on some R&D (research and development) projects for specialised equipment manufacturers that currently use diesel engines to power their off-highway vehicles.”
Australian EVS isn’t trying to replace the entire vehicle fleet overnight. Instead, the company is offering a practical, engineered pathway for operators to transition gradually without compromising on performance or reliability.
“Our speciality is bespoke EV engineering for the real world,” Higginson said. “We help fleets keep the vehicles they already know and trust – but cleaner, quieter, and far more efficient.”
This article appeared in the Winter edition of Mining Magazine.
