By Brazil Stock Guide – A vehicle electrification project backed by Embrapii is offering Brazil a pragmatic route to decarbonize urban transport by retrofitting existing fleets rather than relying solely on new electric vehicle sales. Developed by the Embrapii Powertrain Unit at the University of São Paulo (USP) in partnership with Alpha 6, through its startup EcoSave, the initiative converts Renault Master vans from internal combustion engines to fully electric powertrains using 100% Brazilian-developed technology.
Structured in two sequential Embrapii-supported projects, the program served as a learning and validation platform for national engineering capabilities in electromobility. “It was our first vehicle electrification project within the Embrapii unit, and we learned a great deal,” said Bruno Angélico, a researcher at the Embrapii Powertrain USP unit, highlighting the initiative’s role in building domestic know-how.
The first phase focused on feasibility studies and simulations. USP engineers mapped real-world driving routes in São Paulo’s southern zone to create a virtual operating environment, allowing them to size the electric powertrain — motor, inverter and battery pack — according to actual usage patterns. The second phase addressed the system’s core: development and validation of the powertrain control logic, ensuring torque delivery and throttle response comparable to combustion engines to minimize adaptation challenges for drivers.
Key components, including the electric motor and inverter supplied by Brazilian manufacturer WEG, underwent extensive bench testing at USP’s Institute of Energy and Environment (IEE), one of the few facilities in Brazil accredited for testing electric machines. The tests validated performance, durability and safety under conditions designed to replicate real fleet operations.
Economics and regulation
The choice of the Renault Master was deliberate. The model has led Brazil’s van market for nine consecutive years, with an estimated 200,000 units currently in operation. “We selected one of the most widely used vehicles in Brazil, which naturally offers the greatest transformation potential,” said Leandro Zillig, director at Alpha 6. The conversion kit replaces the combustion engine with an electric traction system while preserving the vehicle’s original structure and peripherals.
According to the project partners, the retrofit solution reduces the cost of deploying electric fleets by 30% to 40% compared with purchasing new electric vans, extending the useful life of existing assets while delivering emissions reductions. The approach aligns with Brazil’s ESG commitments and with regulations such as São Paulo’s Municipal Law No. 16,802, which mandates that 50% of vehicle fleets be electrified by 2028 in the city.
Testing and next steps
The electric van prototype is now entering its final preparation stage for on-road testing, with plans to log approximately 5,000 kilometers to assess robustness and long-term reliability. Early performance has exceeded expectations: projected driving range rose from 200 kilometers to about 250 kilometers, supported by efficient regenerative braking. That range comfortably surpasses the daily needs of typical operators such as school transport providers, who average roughly 120 kilometers per day.
The successful completion of the project underscores Brazil’s capacity to develop competitive electromobility solutions domestically, while positioning vehicle retrofitting as a viable business model for fleet decarbonization. By combining cost efficiency, regulatory alignment and local engineering, the Embrapii-backed initiative points to a scalable path for reducing emissions in Brazil’s light commercial transport sector.
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