New Flyer Unveils Extended Range Hydrogen Bus Upgrade

Minnesota, USA- New Flyer of America Inc., a subsidiary of NFI Group Inc., zero-emission mobility solutions, has introduced a key enhancement to its 40-foot Xcelsior CHARGE FC hydrogen fuel cell-electric bus (FCEB). The company unveiled an optional four-tank hydrogen module that significantly increases the bus’s onboard fuel capacity by 17.5 kilograms a 50% boost over the standard configuration. This upgrade extends the vehicle’s range by up to 120 miles, offering greater operational flexibility and longer route coverage.

The innovation is being deployed in partnership with the Humboldt Transit Authority in Northern California, where the system has already demonstrated strong performance on steep and demanding routes. Humboldt was among the first to adopt the extended-range configuration, and results have exceeded expectations in both reliability and fuel economy.

The four additional transverse-mounted tanks work alongside the existing five standard tanks to provide enhanced capacity without compromising vehicle layout. New Flyer’s advanced hydrogen technology includes a lightweight, high-efficiency fuel cell module, recyclable high-power batteries, enhanced waterproof battery enclosures, and a powerful electric drive system capable of recovering up to 90% of braking energy.

The range extension is based on Federal Transit Administration (FTA) test data from Penn State’s Altoona Bus Testing Center, where similar buses demonstrated an average fuel efficiency of 7 miles per kilogram. With the added hydrogen capacity, this translates to up to 120 extra miles of driving range a game changer for transit agencies seeking longer, uninterrupted service on fuel cell buses.

With this latest development, New Flyer continues its legacy of innovation in sustainable public transportation, helping transit operators meet clean energy goals while enhancing fleet performance.

Mr. Greg Pratt, General Manager, Humboldt Transit Authority, said, “We are excited to be the first public transit agency in North America to adopt this extended range feature from New Flyer. Performance in both fuel economy and range has exceeded our expectations, enabling more dependable service for our community. We are proud to showcase New Flyer’s technology here and demonstrate how forward-thinking solutions can benefit both the environment and the people we serve.”

Ms. Jennifer McNeill, Vice President, Sales and Marketing, New Flyer and MCI. “Mobility solutions should work for every community, whether in rural counties or growing cities. We are excited to offer this extended range feature to support our customers with longer service routes, more aggressive duty cycles, and harsher climates.”

Mr. Chris Stoddart, President, North American Bus and Coach, NFI, said, “With zero-emission buses, range matters, and this upgrade is a game-changer. We’re driving innovation at NFI to ensure our zero-emission models match or outperform traditional propulsion modes in efficiency, reliability, and performance.”

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