First Mode and SMS Equipment see strong hybrid retrofit potential for deep-pit operations across Canada
Canadian mining operations are prime candidates for incorporating hybrid power solutions into their haul truck fleets.
First Mode, which operates within Cummins, is developing a hybrid power system to retrofit electric-drive haul trucks in the 200-tonne payload size class. The hybrid powertrain is currently being field tested in Chile on two Komatsu 930E-4 trucks and First Mode is in active discussions with several miners in Canada.
Canada’s deep-pit mines, which are downhill loaded or uphill loaded, are an ideal operation for hybrid haul trucks due to the amount of braking required to navigate the site. The hybrid system uses regenerative braking, which harnesses the energy created by braking to help charge the onboard battery.
“The more you brake, the more you deposit energy into the batteries and recharge them,” said Molly Puga, General Manager of First Mode at Cummins. “By our math, Canada should be the best haul routes in the world for hybrids.”
First Mode was founded in 2018 by a team of aerospace engineers that wanted to assist mining companies navigate their path to decarbonization. The company began developing hydrogen solutions for mining equipment before pivoting to hybrid energy systems. First Mode was acquired by Cummins in 2025.
“It’s been a really good marriage,” Puga said. “I think we have a lot of complementary strengths that are going to make hybrids more impactful and more of a real solution for the market.”
One of those strengths is Cummins’ 60-year partnership with Komatsu. With Cummins engines already powering Komatsu’s haul trucks, First Mode can fine tune both the electric and diesel components to work in harmony to move the machines.
“One of the benefits of Cummins buying First Mode is we can optimize both sides of the powertrain, so not just the batteries. We can kind of control how the engine runs too,” Puga said.
Komatsu’s global network of dealers is also able to connect First Mode with fleet owners that are ideal candidates for a hybrid retrofit. In Canada, First Mode is working with SMS Equipment to develop partnerships.
“Specific to Canada, we really see a significant opportunity with existing fleets, because it’s a retrofit solution,” said Dillon McKinnon, SMS Equipment’s Manager of Mining Equipment Technology. “About 85 per cent of the haul trucks that we support fit into this electric-drive category.”
To retrofit a haul truck, First Mode installs batteries, a conversion module and a control module that regulates how energy flows between the batteries and the engine. The retrofit is completed on-site in a matter of weeks. The deck of the truck is removed and replaced with the large batteries that range from 185 kWh up to 1.4 MWh.
“Retrofitting a truck is not for the faint of heart,” Puga said.
The prototype 930E-4 trucks operating in Chile launched in February and March and have accumulated about 2,100 hours. So far, the trucks have recorded fuel savings of about 15 per cent. To put that into context, the average diesel budget for a haul truck was US$1 million before prices skyrocketed due to conflict in the Middle East.
“We’re excited. The 15 per cent is our initial result. The trials running in Chile are essentially a more robust prototype. As we look towards our future product roadmap, the next iterations should deliver more than that,” Puga said.
The 15 per cent fuel reduction also translates to a 15 per cent reduction in emissions. However, the savings extend beyond fuel burn. Haul trucks generally operate at peak power, which isn’t optimal for the engine. A hybrid powertrain helps relieve the diesel engine of a portion of the operational strain. As well, the use of the electric motor extends the required maintenance intervals of the diesel components.
“These large-scale industrial engines are rated on total litres or gallons burned over their lifetime. So, you’re also extending the life of that engine by that equivalent amount. You’re getting an engine that’s lasting 15 per cent longer,” McKinnon said. “It’s even potentially longer because you’re not loading it as hard.”
Payload impact
The current hybrid powertrain weighs about eight tonnes, about three per cent of a truck’s payload, which First Mode expects will significantly decrease in future versions.
“When we work with mines, we find that very rarely do they load them to the theoretical limit. If they do, it’s only about two per cent of the time,” Puga said. “So, the payload impact depends a little bit on how miners are loading their trucks.”
While payload is slightly reduced, a hybrid powertrain does boost productivity as it provides power to the wheels faster than a traditional diesel engine.
“We’re already seeing reduced cycle times,” McKinnon said. “They’re able to basically offset some of that spool-up time as you’re on and off the throttle with the engine. Throughout the day you’re getting more loads in as you shorten the cycle time from point A to B.”
McKinnon explained reducing fuel consumption is a common goal of Canadian miners to meet environmental goals, lower costs and address infrastructure challenges. The retrofit option provides a solution that is scalable and doesn’t require major capital investments or building new infrastructure.
“It’s very flexible in how you deploy it or how fast you deploy it. So, it gives a practical way to start reducing fuel and reducing emissions without waiting for a fully electrified solution,” he said. “You can put it on one truck, you can put it on 10 trucks or you can do the whole fleet.”
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While a hybrid retrofit might be seen as part of the path to mine electrification for some mine operators, others are eyeing it as a long-term fleet strategy.
“This really fills that gap of being able to do something, utilize existing assets and start working down that pathway to not just decarbonization, but also a lower cost per tonne,” McKinnon said.
While First Mode started with a hybrid powertrain for the 930E-4, the company is now developing similar solutions for multiple Komatsu haul truck platforms. The company is currently in talks with an SMS customer to develop a hybrid system for the 230-tonne 830E and is working to scale the solution for the larger 360-tonne 980-series trucks.
“We’re working with Komatsu on all that. We signed an MOU with Komatsu Mining Technologies last year and we committed to supporting these pilots and trials mutually, but also working to develop a Komatsu-blessed factory solution for the market,” Puga said.
Currently, First Mode plans to focus its hybrid drivetrain research and development on mining trucks, but its scope may expand in the future.
“If you can make it work in mining, then you should be able to make it work in some of the other industrial markets where Cummins operates — rail, marine, defence, and oil and gas,” Puga said.
