Turnkey hydrogen refueling stations: refueling time and range comparable to diesel operation

• Bosch Rexroth and Bosch Manufacturing Solutions offer a turnkey hydrogen refueling station solution featuring the integrated CryoPump module for simultaneous liquid and gaseous hydrogen refueling.

• The stations can refuel up to eight heavy-duty vehicles per hour, providing a range of approximately 1,000 kilometers, matching diesel refueling times and range.

• The technology reduces investment and operating costs significantly by simplifying station design, cutting high-pressure components, and lowering space requirements.

• Proven in the US with a station at the Port of Oakland and a planned facility for 175 buses, the solution is now expanding to Europe, supported by government funding and focused on rapid, cost-effective infrastructure deployment.

• A comprehensive solution from Bosch Rexroth and Bosch Manufacturing Solutions reduces complexity and project lead times

• Each station refuels up to eight commercial vehicles per hour, providing a range of 1,000 kilometers

• Simultaneous refueling with liquid and gaseous hydrogen

• Significantly lower investment and operating costs are driving the economic expansion of the infrastructure for commercial vehicles

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Bosch Rexroth and Bosch Manufacturing Solutions are presenting a turnkey solution for hydrogen refueling stations at the Hydrogen Technology World Expo 2026. With this solution, both companies are supporting the cost-effective development and expansion of hydrogen infrastructure for heavy-duty vehicles. A refueling station equipped with a cryogenic pump unit can refuel up to eight heavy-duty trucks per hour, providing an average range of 1,000 kilometers. This enables hydrogen-powered heavy-duty vehicles to achieve competitive conditions in terms of refueling time and range.

The core of the turnkey refueling solution for heavy-duty vehicles is an integrated CryoPump module developed by Bosch Rexroth, which combines central pump, hydraulic, and control functions in one complete solution. At the refueling station, only a liquid hydrogen tank, vaporizer, and dispenser need to be installed.

Using the patented CryoPump the refueling station simultaneously delivers both liquid subcooled and high pressure gaseous hydrogen directly into the tanks of heavy-duty vehicles, thus covering the two concepts prevalent in North America and Europe for hydrogen trucks and buses. Direct refueling of heavy-duty vehicles significantly reduces the technical complexity of hydrogen refueling stations: planning and construction costs are reduced, fewer high-pressure components are required, and the space requirement is smaller. By eliminating the need for high-pressure storage and chiller, the investment costs of the refueling station can be reduced by up to 50 percent.

Hydrogen refueling station for 175 buses under construction

As a compact, complete solution without complex additional modules, the first station with the innovative pump technology has proven its worth since October 2025 at the Port of Oakland, California. Minimal boil-off losses and long maintenance cycles reduce operating costs by up to 70 percent. The experience gained from daily operation has convinced SamTrans, the operator of public buses in San Mateo County near San Francisco. In cooperation with the American hydrogen infrastructure company Fastech, Bosch Rexroth will build a hydrogen refueling station for SamTrans in 2027 to refuel 175 hydrogen buses.

Proven techology now also available in Europe

The market environment in Europe is also developing positively. For example, the Federal Ministry of Transport has set up a 220-million-euro support program for 2026 to support the expansion of hydrogen refueling station infrastructure and the development of hydrogen-powered heavy-duty vehicles.

Bosch Rexroth is also making its field-proven drive and control technology available in Europe. The refueling station with a CryoPump dispenses not only highly compressed gaseous hydrogen but also subcooled liquid hydrogen (sLH2). sLH2 technology is establishing itself primarily in Europe. Bosch Manufacturing Solutions handles the technical planning, project engineering, and integration of all other components and modules. This turnkey solution supports the rapid, cost-effective expansion of hydrogen infrastructure in Europe.

Turnkey solution reduces complexity

The complete solution includes the planning, design and commissioning of hydrogen refueling stations. An innovative electrohydraulic solution based on highly available series components and the modular design reduce the complexity and shorten the project runtimes. The efficient direct filling of heavy-duty vehicles and the robustness of the electrohydraulics with long maintenance cycles have proven to reduce investment and operating costs to a new economic level.

Bosch Rexroth and Bosch Manufacturing Solutions at the Hydrogen Technology World Expo: Hall B6, booth 6C14.