Logistics Depot Smart Charging: How a 50-Van Fleet Cut Energy Costs by 40%
For logistics operators, fleet electrification is not just about replacing diesel vans with electric ones. The real challenge is managing charging costs without compromising delivery schedules. This case study shows how a regional logistics company in Zhejiang Province used FBK POWER's smart charging solution to cut depot energy costs by 40% while maintaining 100% fleet readiness.
Client Profile
- Fleet size: 50 electric delivery vans (last-mile urban delivery)
- Daily operation: 6 AM - 10 PM, 6 days per week
- Average daily mileage: 120 km per van
- Depot location: Industrial zone with time-of-use electricity pricing
- Previous setup: 20 x 7kW AC chargers, unmanaged charging
The Problem: Unmanaged Charging Was Expensive
Before FBK POWER's intervention:
- All vans plugged in at 6 PM when drivers returned
- Peak demand charges reached ¥180,000/month ($25,000)
- Grid connection was at 85% capacity, limiting expansion
- 3-4 vans daily had insufficient charge for morning routes
Smart Charging Solution
FBK POWER replaced the unmanaged AC setup with an intelligent DC charging system:
| Component | Specification | Quantity |
|---|---|---|
| Wall-Mounted AC Charger | 22 kW, OCPP 1.6 | 30 units |
| Split-Type DC Cabinet | 120 kW | 2 units |
| Smart Load Controller | AI-driven scheduling | 1 system |
| Energy Monitoring | Real-time power tracking | 1 platform |
Smart Charging Algorithms
The system uses three optimization strategies:
- Time-of-Use Shifting — Delays non-urgent charging to off-peak hours (11 PM - 6 AM)
- Load Balancing — Distributes available power across all connected vehicles
- Priority Scheduling — Charges vehicles with early morning routes first
Implementation Timeline
| Week | Activity |
|---|---|
| 1-2 | Site audit, electrical assessment |
| 3-4 | Hardware delivery, installation |
| 5 | Software configuration, integration |
| 6 | Driver training, go-live |
| 7-12 | Optimization tuning, data collection |
Results After 12 Months
| Metric | Before | After | Improvement |
|---|---|---|---|
| Monthly Energy Cost | ¥180,000 | ¥108,000 | 40% reduction |
| Peak Demand Charge | ¥85,000 | ¥32,000 | 62% reduction |
| Fleet Readiness | 92% | 100% | +8 percentage points |
| Average Charge Time | 8 hours | 5.5 hours | 31% faster |
| CO2 Emissions | 180 tons/year | 45 tons/year | 75% reduction |
How Smart Charging Works
The Algorithm in Plain Terms
Every evening at 6 PM, the system receives:
- Next day's route schedule (which vans leave at what time)
- Each van's current state of charge
- Electricity price forecast for the next 24 hours
- Grid capacity limits
The algorithm then builds a charging schedule that:
- Ensures every van has sufficient charge before departure
- Minimizes total electricity cost
- Keeps peak demand below grid capacity
- Extends battery life by avoiding unnecessary fast charging
Driver Experience
Drivers plug in when they return. The system handles everything else. A mobile app shows:
- Estimated full charge time
- Current charging speed
- Tomorrow's route readiness
Scalability to 100+ Vehicles
The same depot is now expanding to 80 vans. Because the smart charging system was designed for growth:
- No additional grid connection required (load balancing handles it)
- Software license scales with vehicle count
- Hardware additions are plug-and-play
Lessons for Logistics Operators
- Smart charging pays for itself — ROI in 14 months through energy savings alone
- Driver behavior matters — training on plug-in discipline improved readiness by 5%
- Data drives optimization — 6 months of operational data refined the algorithm significantly
- Start with AC, add DC for peak shaving — hybrid approach is most cost-effective
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