EV Charging Case Studies: 5 Deployments Across Fleets

EV Charging Case Studies: 5 Deployments Across Gas Stations, Mines, Fleets, and Warehouses

Key Takeaways

• Five real deployments covering gas stations (Sinopec, 100+ sites), mining (1,610 kW hub), municipal fleets (120 vehicles), e-commerce distribution (150 trucks), and last-mile logistics (50 vans).
• Common thread: each project started with a specific operational constraint (uptime, grid capacity, cost, or schedule) and was solved by matching the right hardware architecture to the site.
• Use this page to find the case closest to your situation, then read the full breakdown for specs, timeline, and lessons learned.

When we talk to fleet operators, gas station owners, or municipal procurement teams, the first question is rarely "what can your chargers do" and more often "have you done this before, in a situation like mine." This page collects five deployments we have completed, organized by use case. Each one started with a constraint that off-the-shelf solutions could not solve, and each one required a different combination of hardware, power management, and on-site engineering.

We are not listing these to impress anyone with big numbers. We are listing them because the details matter more than the headline: a 1,610 kW mining hub is useless to a gas station owner, and a 50-van logistics depot teaches different lessons than a 150-truck distribution center. If one of these matches your situation, the linked case study goes deeper into the equipment list, the problems we hit, and what we would do differently.

1. Gas station network: 100+ sites in six months

The client operates one of the world's largest gas station networks, with more than 30,000 locations. They needed to add DC fast charging to highway rest stops and urban stations without disrupting fuel operations, and they needed it done before the summer travel season.

The scope: more than 100 sites, over 400 charging ports, averaging 180 kW per port. The constraint: many sites had limited grid capacity, and the client required a single vendor responsible for both the power cabinets and the dispensers, with remote monitoring across the entire network.

We deployed split-type DC fast charging systems. The power cabinets sit in the equipment area, and the dispensers sit at the charging bays. This separation matters for gas stations because it keeps the high-voltage equipment away from the fuel islands and allows the dispensers to fit into existing parking spaces without major civil work.

The result: all sites commissioned within six months. The network has maintained 99.2% uptime across the first year of operation. The client has since expanded the contract to additional regions.

Read the full case study: Sinopec gas station EV charging case study

2. Mining fleet: 1,610 kW charging hub in a remote location

The client operates an open-pit iron ore mine, 200 km from the nearest city, with 45 heavy-duty haul trucks running three shifts daily. The goal was to replace diesel trucks with electric ones without reducing daily tonnage.

The constraint was not just power. The site had limited grid capacity, extreme temperature swings from -20°C to +45°C, and dust levels that destroy standard air-cooled electronics. The trucks needed 300-500 kWh per shift, which meant high-power DC charging during the brief windows between shifts.

We designed a 1,610 kW charging hub using liquid-cooled power cabinets rated for the temperature range, with IP65-rated enclosures for the dispensers. The system staggers charging across shift changes to stay within the site's grid limit, and it uses OCPP 1.6 to integrate with the mine's fleet management software.

Read the full case study: Mining fleet electrification case study

3. Municipal fleet: 120 vehicles, 80% energy cost savings

A mid-sized city in Southern California needed to electrify 120 vehicles across sanitation, public works, and administration. The fleet ran on diesel and gasoline, with an annual fuel cost of $520,000. The city council mandated 50% electrification by 2028, but the public works yard had only 500 kVA of available capacity.

The solution combined DC fast charging for the sanitation trucks (which run fixed routes and return to the yard twice daily) with AC charging for the administrative vehicles. We added a 500 kWh battery energy storage system to shave peak demand and avoid a $300,000 grid upgrade. The storage system charges during off-peak hours and discharges during the evening peak when the sanitation trucks return.

The result: 80% reduction in energy costs compared to diesel, with 100% operational readiness maintained. The city has since expanded the program to a second depot.

Read the full case study: Government fleet EV charging case study

4. E-commerce distribution center: 150 trucks with battery storage

A major e-commerce distribution center in the Midwest needed to charge 150 electric delivery trucks. The warehouse had a 1,500 kVA service, but the trucks required 3,000 kW of charging capacity during the two-hour window between the evening return and the morning dispatch.

The constraint: a grid upgrade would cost $450,000 and take 14 months. The client needed the trucks operational in six months to meet a customer sustainability commitment.

We installed a 2 MWh battery energy storage system that charges overnight at 500 kW and discharges at 1,500 kW during the evening peak. The DC fast chargers draw from the battery, not the grid, during the critical window. The system also provides backup power for the warehouse's critical loads during outages.

The result: 98.2% charging uptime in the first year, with grid infrastructure costs reduced by 50% compared to the original upgrade plan.

Read the full case study: Warehouse distribution center EV charging case study

5. Last-mile logistics: 50 vans, 40% energy cost reduction

A regional logistics company in Zhejiang Province operated 50 electric delivery vans from a single depot. The vans ran six days per week, returning at 6 PM and departing at 6 AM. The depot had 20 existing 7 kW AC chargers, but the fleet manager had no control over when the vans charged.

The problem: all 50 vans plugged in at 6 PM, creating a 350 kW demand spike that triggered the highest time-of-use tariff. The monthly demand charge alone was $4,200, and the fleet was growing.

We replaced the unmanaged chargers with 30 smart AC chargers and added a central energy management system. The system staggers charging based on each van's next-day route requirements, prioritizing vehicles with early departures and high mileage. Vans with lighter schedules charge after midnight when rates drop.

The result: 40% reduction in energy costs, with the demand charge eliminated. The system pays for itself in 14 months.

Read the full case study: Logistics depot smart charging case study

What these deployments have in common

The hardware varies. The sites vary. But the pattern is consistent: the successful projects started with a clear operational constraint, not a desire to "go electric." The gas station network needed to avoid disrupting fuel sales. The mine needed to maintain tonnage. The city needed to avoid a grid upgrade. The warehouse needed to hit a deadline. The logistics depot needed to cut costs.

The second pattern is that off-the-shelf solutions rarely work at this scale. Every one of these projects required custom engineering: split-type power cabinets for the gas stations, liquid cooling for the mine, battery storage for the city and the warehouse, and smart charging software for the logistics depot.

If you are evaluating EV charging for a fleet, a gas station, or a distribution center, the first step is not picking a charger. It is defining the constraint that will make or break the project. Once that is clear, the hardware choice follows.

Related reading

• NEVI eligible EV charger vendors 2026
• Buy America compliant EV charger manufacturers
• EV charger factory audit guide
• EV charger total cost of ownership

If you have a project that resembles one of these cases, or one that does not, contact our project team or request a quote with your site details.