01 / Client Overview
Client Overview
A regional last-mile delivery company operating 50 diesel vans in a major metropolitan area sought to electrify their fleet to reduce fuel costs, meet emissions regulations, and improve their sustainability profile.
The fleet operated on a hub-and-spoke model: vehicles departed from a central depot at 6 AM, made 80-120 deliveries per day, and returned by 6 PM for overnight charging. The depot had limited electrical capacity, requiring creative load management.
02 / The Challenge
The Challenge
Limited Electrical Capacity
The depot had only 200kW electrical service, but 50 vehicles × 7kW AC charging would require 350kW. Upgrading utility service would cost $80,000 and take 6 months.
Charging Window Constraints
Vehicles returned between 5-7 PM and departed at 6 AM, giving a 12-hour charging window. However, not all vehicles returned simultaneously, creating peak demand spikes.
Cost Sensitivity
As a mid-sized operator, the client needed a solution that minimized both capital and operating costs while delivering reliable charging.
03 / The Solution
The Solution
Smart Load Management
FBK POWER's intelligent load management system distributed 200kW across 20 charging ports based on vehicle state-of-charge and departure time. Priority charging for vehicles with earliest departure times.
Mixed AC/DC Strategy
10 × 7kW AC chargers for vehicles with lighter duty cycles and 10 × 20kW DC chargers for high-mileage vehicles. This balanced cost and charging speed.
Time-of-Use Optimization
Charging scheduled during off-peak hours (10 PM - 6 AM) reduced electricity costs by 40%. Vehicles arriving before 10 PM were queued and started charging at the optimal time.
04 / Implementation
Implementation
Fleet Analysis (Week 1-2)
Analyzed 30 days of fleet data: daily mileage, return times, battery states, and parking patterns. Identified that 60% of vehicles needed only 7kW AC charging.
System Design (Week 3-4)
Designed charging layout with 10 AC pedestals and 10 DC fast dispensers. Load management algorithm optimized for 200kW service limit.
Installation (Week 5-6)
Installed charging infrastructure without disrupting daily operations. Weekend work for electrical panel upgrades.
Go-Live (Week 7)
Phased rollout: 10 vehicles in week 1, 20 in week 2, full fleet by week 3. Driver training on charging procedures and mobile app.
05 / Results & Impact
Results & Impact
Key Metrics
- • 50 vehicles fully electrified within 7 weeks
- • 200kW service limit maintained (no utility upgrade needed)
- • 100% vehicles charged by 6 AM departure
- • 40% reduction in electricity costs via time-of-use
- • 97.2% charging uptime
- • $180,000 annual fuel cost savings
- • $45,000 annual maintenance savings
- • 60% reduction in CO2 emissions
- • 4.5/5.0 driver satisfaction rating
- • ROI achieved in 3.2 years
"FBK POWER's load management system was the key to making fleet electrification work within our electrical constraints. We avoided an $80,000 utility upgrade and still charge all 50 vehicles overnight."