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Tesla Semi joins DHL’s US logistics fleet and takes on diesel

White Tesla semi-truck branded with DHL logo inside a modern warehouse with large windows and polished floor.

Diesel is no longer untouchable, and the German logistics multinational is convinced of it. Tesla’s all-electric truck has just shown it has what it takes to earn a place in major distribution fleets.

A little over a year ago, the Tesla Semi was already being trialled by DHL, while Elon Musk was confidently pointing to availability the following year-after a production ramp-up that had been anything but smooth. Now it is 2025 and, for once, a pledge from Tesla’s CEO has broadly materialised: the Semi is heading out on the road.

The Tesla Semi has not yet been welcomed with open arms by hundreds of companies, but DHL has now officially added its first Semi to its logistics network in the United States. That is a strong start for a vehicle that many commentators had dismissed as operationally impractical. DHL, after all, is one of the world’s leading transport and logistics groups-there are far worse places to begin.

A road-going giant: tough and economical

DHL did not make the decision on a whim. The company only committed after an extended pilot programme in Livermore, California. By the end of that programme, the Semi’s efficiency had been clearly demonstrated: over a journey of roughly 628 km, with a gross combination weight of 34 tonnes (truck plus load), average consumption came in at just 1.07 kWh/km, or 107 kWh/100 km.

Efficiency numbers from the 628 km Tesla Semi route

For a truck in this class, that figure is exceptional-especially given Tesla’s 2017 promise that the Semi would come in “under 2 kWh per mile” (around 1.24 kWh/km). Plenty of specialists doubted those numbers. DHL’s results indicate not only that it can be done, but that the target has been beaten by a wide margin-even with a trailer loaded to the roof.

Jim Monkmeyer, President of DHL Supply Chain North America, shared the news with clear enthusiasm: “Our trial phase exceeded our expectations. The Tesla Semi proved it can carry our goods over long distances on a single charge. This is an essential milestone in our decarbonisation goals.” In his view, the stated range-up to 800 kilometres-“opens up possibilities that were previously out of reach for electric heavy goods vehicles”.

Energy costs and maintenance savings

The single truck currently operating in DHL’s fleet covers about 160 km per day on average and only needs to plug in once per week. That helps bring operating costs down sharply: with consumption this low, the energy cost averages between 12 and 15 euro cents per kilometre.

Against an equivalent diesel truck, typically costing between 34 and 47 euro cents per kilometre for energy, the gap is huge. In other words, the Semi can cut the energy bill by up to 75%. And that is before factoring in maintenance savings-an area that weighs heavily on diesel fleets-because an electric drivetrain means far fewer visits back to the workshop.

Even if the upfront price is higher (in the US, the Semi costs more than $200,000, versus roughly $120,000 for a basic diesel truck), the extra outlay can be recovered within a few years for a vehicle that is used daily.

A strong piece of publicity for Tesla

For Tesla, this partnership is highly valuable, because DHL is among the sector’s biggest potential buyers-and its adoption could encourage other international hauliers to follow. Walmart, Costco and Sysco are among the major customers that have already placed orders. Programme Director Dan Priestley says the company has “logistics expertise [that] will help improve the Semi for its future markets”.

DHL’s expansion plans for the Tesla Semi

DHL has been steadily reducing its reliance on diesel for several years and already runs more than 150 electric heavy goods vehicles in North America. The group intends to grow that fleet further by adding more Tesla Semis from next year, once the manufacturer finally begins mass production.

That is welcome news for the US carmaker after a year of setbacks that have badly damaged its reputation (perhaps rightly, but that is not the point here). Nearly eight years after it was unveiled, the Semi can at last cruise the wide American highways, while major companies look on with envy-rather like the misunderstood kid everyone mocked at break time, returning a few years later to take well-deserved revenge.

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