Custom Denning and Forsee Power strengthen position in zero-emission transit market

Australia’s transition to zero-emission public transport is accelerating, and Custom Denning, the country’s oldest bus manufacturer, is leading the charge with its Element 2 electric bus. The company has ramped up production of the Custom Denning electric bus, powered by Forsee ZEN PLUS battery systems, to meet growing demand. More than 150 Element 2 electric buses are already in operation, with additional units set to be deployed in the coming months.

Custom Denning’s expansion aligns with the New South Wales Government’s goal of replacing its 8,000 diesel buses with electric alternatives. The state aims to fully convert Greater Sydney’s fleet by 2035, followed by a complete transition for the rest of the state by 2047. The manufacturer, which builds its buses at its Western Sydney facility, is also expanding its footprint internationally, supplying its vehicles to the Rotala network in the United Kingdom.

What Makes the Element 2 Electric Bus Stand Out?

The Element 2 electric bus has been engineered to meet the specific needs of urban transit networks. Equipped with the Forsee ZEN PLUS battery system, the bus offers an impressive range of 500 km on a single charge. Its onboard energy capacity of 462 kWh ensures that it can complete full-day operations without requiring a mid-route recharge.

Forsee Power, a French company specializing in high-performance battery systems, has become a major supplier for the global electric bus market. The Forsee ZEN PLUS battery system uses NMC lithium-ion technology, which balances high energy density with long-term durability. These batteries are designed to last 5,000 cycles, reducing overall maintenance costs and improving the total cost of ownership (TCO) for transit operators.

The technology is also optimized for both overnight slow charging and fast charging. This flexibility is crucial for transport authorities looking to balance operational efficiency with infrastructure costs. Last month, Transport for New South Wales (TfNSW) observed a live demonstration of pantograph fast charging, where the Element 2 electric bus successfully completed multiple 1C fast-charging sessions. The ability to recharge in under an hour makes these vehicles highly adaptable to high-frequency urban routes.

Why Is Australia Prioritizing Electric Buses?

Australia has historically been slow in adopting electric public transport compared to Europe and North America. However, as concerns over urban air pollution, fuel costs, and climate change intensify, government policies are now driving widespread electrification. The Australian Renewable Energy Agency (ARENA) and state governments have introduced various funding initiatives to support the transition.

The electrification of buses is particularly significant because public transport fleets contribute significantly to urban emissions. A study by the Australian Electric Vehicle Council highlighted that transitioning to electric buses could cut transport-related emissions by up to 40% in key metropolitan areas. With fuel and maintenance savings factored in, electric buses are increasingly seen as a financially viable alternative to traditional diesel models.

How Is Forsee Power Supporting the Global Shift to Electrification?

Forsee Power has positioned itself as a leading provider of battery solutions for electric buses, with more than 4,200 vehicles globally equipped with its systems. Unlike some competitors, the company has focused on scalability and energy efficiency, ensuring that its batteries cater to a wide range of applications, from urban transit to long-distance travel.

The Forsee ZEN PLUS battery system stands out for its liquid thermal management, which enhances energy efficiency and longevity. This technology prevents overheating, ensuring consistent battery performance in extreme temperatures—an essential feature for Australia’s diverse climate.

Beyond performance, Forsee Power has built its reputation on sustainability. As a signatory of the UN Global Compact, the company follows strict environmental, social, and governance (ESG) standards. It has integrated third-party ESG audits, conducted by Bureau Veritas, to evaluate supplier compliance with ethical and environmental regulations. The company has also committed to decarbonizing its supply chain, with its emissions reduction targets validated by the Science-Based Targets initiative (SBTi).

How Does Custom Denning’s Manufacturing Approach Support Sustainability?

Custom Denning has long been known for its focus on local manufacturing and high-quality engineering. The company ensures that each Custom Denning electric bus is tested under real-world Australian conditions before deployment. Its engineering teams are actively integrating renewable energy solutions into production processes, reinforcing its commitment to sustainable manufacturing.

“As a company, we prioritize both ethical and responsible manufacturing,” said Simon Fitzgerald, Head of Engineering at Custom Denning. He emphasized that Forsee Power’s leadership in battery sustainability made them a natural partner for Custom Denning’s zero-emission bus strategy.

What’s Next for Electric Bus Adoption in Australia?

With New South Wales leading the transition, other states are expected to follow suit. Cities like Melbourne and Brisbane are already conducting electric bus trials, and federal support for charging infrastructure is increasing.

For Custom Denning, the focus remains on scaling production capacity to meet the growing demand. The company is also exploring opportunities in other international markets where governments are seeking reliable, long-range electric buses.

Forsee Power, meanwhile, continues to expand its influence across Asia-Pacific, working with various transit operators to tailor battery solutions for different charging and route needs. Frederic Poupeau, Vice President Asia-Pacific at Forsee Power, noted that their expertise extends beyond just battery production—they also provide aftersales services and lifecycle support, ensuring that operators maximize their investment in electric fleet technology.

Australia’s shift toward zero-emission public transport represents a pivotal moment for both Custom Denning and Forsee Power. As production ramps up and policies continue to support electrification, the next decade could see a complete transformation in how Australians commute.