First Mode operates within Cummins, combining deep hybrid‑system expertise with Cummins’ global engineering, manufacturing and service network.
Cummins acquired First Mode to accelerate the deployment of practical hybrid‑electric solutions that reduce fuel use and emissions now, without requiring new infrastructure, while supporting customers on the path toward lower‑carbon operations.
Together, the teams are scaling retrofit hybrid systems designed for real‑world mining conditions, backed by Cummins’ global footprint and long‑term support capabilities.
Proven hybrid performance for today’s mining fleets
A practical hybrid retrofit
Real operational benefits
Designed for ultra‑class mining
Why choose hybrid
Lower total cost of operation
Designed for real‑world mining performance, the system cuts fuel use, reduces engine and brake wear and can improve cycle times while meeting 2–3‑year payback targets. It lightens load on critical truck systems, increases refueling intervals, lowers retarding noise and extends the life of existing fleets.
Immediate emissions impact
Hybrid systems reduce diesel consumption and CO₂ from the first day of operation, with results shaped by each site’s duty cycle and terrain. By capturing braking energy typically lost as heat and returning it to the drive system, the hybrid meaningfully offsets fuel use. Deploying a trial unit helps miners confirm real‑world benefits and optimize performance as Cummins continues to enhance the technology.
Infrastructure‑free deployment
No charging systems, no hydrogen and no new infrastructure required. Unlike trolley or static charging, the hybrid demands no added site investment and keeps full operational flexibility. Operators change nothing about how they drive, making adoption effortless.
Built for operational continuity
Hybrid today with a clear path to BEV/FCEV tomorrow, the system supports Cummins’ Destination Zero roadmap by enabling smooth, sequential progress toward future powertrains. Its fail‑to‑normal architecture keeps trucks operating even when the hybrid is offline, protecting productivity. Designed for safety, reliability and ease of maintenance, it performs in the most demanding mining environments.
Hybrid Electric Retrofit Architecture
Designed for 200T+ electric-drive mining haul trucks, this hybrid-electric retrofit helps mining operators reduce fuel consumption, lower emissions, improve productivity and enhance total cost of ownership — without new infrastructure, fleet replacement, or changes to operator workflows.
The system captures energy normally lost during braking and retarding, then redeploys it to reduce diesel consumption and provide additional power when needed, helping increase productivity in demanding mine environments.
Built on a modular architecture of batteries, power electronics and intelligent controls, the solution integrates directly with existing electric-drive systems and can be tailored to site-specific duty cycles. The result is a practical, commercially deployable decarbonization pathway that delivers more power, less fuel consumption and no operational disruption.
Technical specifications
This hybrid system combines a rugged diesel–electric architecture with a modular battery, high power regenerative braking and intelligent power electronics. By reclaiming braking energy typically lost as heat and returning it to the drive system, it significantly reduces diesel consumption and improves efficiency. Purpose engineered components, thermal management, structural reinforcement and robust mounting hardware, ensure dependable performance across tough mining environments. The flexible architecture adapts to any duty cycle or fleet strategy, enabling seamless retrofit or first fit integration.
A purpose-built control system integrates the hybrid battery with the truck’s traction drive for seamless performance, requiring no change in operator driving habits. Its fail to normal design keeps the truck fully operational even if the hybrid is offline, protecting productivity. Layered safety features, intelligent battery management, advanced thermal monitoring and rugged protection systems, are reinforced by Cummins’ global engineering expertise to ensure dependable operation in the toughest mining conditions.
Purpose built for the harshest mining environments, the system features a rugged, long life battery pack engineered for extreme heat, altitude and heavy loads. A proprietary DC/DC converter adapts instantaneously to drive system voltage for maximum performance and protection, supported by advanced thermal management for stable operation. Typical installation takes only 3–7 days, reducing downtime and accelerating measurable fuel and emissions benefits.
Designed for leading OEM electric drive haul truck families, the hybrid system is already proven across major ultra class platforms. Its retrofit architecture protects fleet flexibility, lengthens equipment life and avoids the cost and complexity of truck redesigns or infrastructure upgrades. With safety, reliability and maintainability engineered for the toughest mining conditions, it delivers a smooth, low risk path into hybrid fleet operations.
Battery energy storage systems (BESS) are arguably the most critical element in creating a resilient, flexible grid with high renewable energy penetration.
First published by International Mining, May 2025 Decarbonizing mining is challenging.
The Cummins Destination Zero strategy seeks to meet customers where they are in the energy transition to zero carbon, zero emissions solutions by providing lower-carbon solutions for every step of the way.
Sustainability is not new to Cummins Inc.
At MINExpo 2024, Cummins Inc. expanded on how bridge technologies will be used to support the mining industry's energy transition.
At a press event on October 29, 2024, Cummins Inc.
Just like a person needs a well-equipped desk to work, the trucking industry needs robust infrastructure to operate efficiently.
Twenty-two 1000 hp Cummins Inc. CustomPaks, built in Australia and equipped with Weir Multiflo high-capacity dewatering pumps, have been delivered to one of the world’s largest coal mining contractors for dewatering operations in Indonesia.
Global support
Deployment services
Lifecycle support
