The Business Case for EV Fleets
Companies across industries are electrifying their fleets—and finding significant benefits. Lower fuel costs, reduced maintenance, sustainability goals, and employee satisfaction all drive the transition.
This guide helps businesses plan and implement EV fleet charging infrastructure.
Why Electrify Your Fleet?
Financial Benefits
Fuel Savings:
- Electricity costs 50-70% less than gasoline per mile
- Fleet of 50 vehicles: $100,000+/year savings typical
Maintenance Savings:
- No oil changes, fewer brake replacements
- 30-50% lower maintenance costs
- Less vehicle downtime
Incentives:
- Federal tax credits on vehicles
- Charging infrastructure tax credits (30%)
- State and utility rebates
- Accelerated depreciation
Operational Benefits
- Consistent "fuel" costs (electricity more stable than gas)
- On-site fueling eliminates gas station trips
- Vehicle telematics/charging data integration
- Improved driver satisfaction
Sustainability Benefits
- Reduced Scope 1 emissions
- ESG/sustainability reporting
- Customer and stakeholder expectations
- Regulatory compliance preparation
Fleet Charging Infrastructure Options
Depot Charging (Primary)
What It Is: Charging at your facility where vehicles park overnight
Best For:
- Delivery fleets with predictable routes
- Service vehicles returning to base daily
- Employee vehicles parked during shifts
Typical Setup:
- Level 2 chargers (7-19 kW each)
- One charger per 1-2 vehicles
- Central charging management software
Advantages:
- Lowest per-kWh cost
- Overnight charging = no driver downtime
- Complete control over infrastructure
En-Route Charging (Supplemental)
What It Is: Public DC fast charging during the workday
Best For:
- Long-haul routes
- Vehicles that can't return to depot daily
- Backup for high-mileage days
Typical Use:
- 15-30 minute stops during breaks
- Strategic placement along common routes
Advantages:
- Extends daily range capability
- Flexibility for varying routes
- No infrastructure investment needed
Destination/Customer Charging
What It Is: Charging while vehicles are at customer locations
Best For:
- Service fleets (technicians at job sites)
- Sales teams at customer offices
- Delivery with extended stops
Typical Setup:
- Mobile chargers carried in vehicle
- Customer outlet access (120V minimum)
- Level 1-2 charging during service
Planning Your Charging Infrastructure
Step 1: Assess Your Fleet
Analyze Current Operations:
- Daily mileage per vehicle (average and maximum)
- Parking duration at depot
- Route patterns and predictability
- Future fleet size plans
Calculate Energy Needs:
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Daily energy need = Daily miles ÷ Efficiency (mi/kWh)
Example: 100 miles ÷ 3.5 mi/kWh = 28.6 kWh per vehicle
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Step 2: Determine Charging Strategy
Overnight Charging (Most Fleets):
- 8-12 hours available
- Level 2 sufficient for most vehicles
- Lower infrastructure cost
Fast Charging (If Needed):
- Vehicles need quick turnaround
- Multiple shifts per day
- High daily mileage (200+ miles)
Step 3: Size Your Infrastructure
Number of Chargers:
- Start: 1 charger per 2-3 vehicles (staggered charging)
- Growth: 1 charger per 1.5-2 vehicles
- Full: 1 charger per vehicle (maximum flexibility)
Power Requirements:
| Chargers | Power Each | Total Load |
|---|---|---|
| 10 × L2 | 7.2 kW | 72 kW |
| 20 × L2 | 7.2 kW | 144 kW |
| 5 × DC | 50 kW | 250 kW |
- Existing electrical capacity
- Utility upgrade costs
- Smart charging to reduce peak demand
Step 4: Choose Equipment
Level 2 Chargers (Depot Standard):
- ChargePoint CPF50: Commercial-grade, network-managed
- Enel X JuiceBox Pro: Good value, smart features
- ABB Terra AC: High-power L2 (up to 22 kW)
DC Fast Chargers (If Needed):
- ABB Terra 54: 50 kW, compact
- ChargePoint Express Plus: Scalable to 500 kW
- Tritium RTM: Reliable, modular
Fleet Management Software:
- ChargePoint Fleet
- Geotab
- EVBox Business Portal
- Shell Recharge for Business
Step 5: Plan Installation
Site Assessment:
- Electrical capacity evaluation
- Panel upgrade needs
- Trenching/conduit routing
- Permit requirements
Phased Approach:
- Pilot: 5-10 vehicles, basic infrastructure
- Scale: Expand based on pilot learnings
- Full deployment: Complete fleet transition
Cost Breakdown
Infrastructure Costs
| Component | Cost Range |
|---|---|
| Level 2 charger | $2,000-6,000 each |
| Installation (L2) | $1,000-5,000 each |
| DC fast charger | $25,000-150,000 each |
| Installation (DC) | $10,000-50,000 each |
| Electrical upgrades | $10,000-100,000+ |
| Networking/software | $200-500/year per charger |
Example: 20-Vehicle Fleet
Initial Infrastructure:
- 12 × L2 chargers: $48,000
- Installation: $36,000
- Electrical upgrade: $25,000
- Total: ~$109,000
With 30% federal credit: ~$76,000
Operating Costs
Electricity:
- $0.10-0.15/kWh (commercial rates)
- 100 miles/day × 250 days × 20 vehicles = 500,000 miles
- Cost: ~$14,000-20,000/year
vs. Gasoline:
- Same miles at 25 MPG, $3.50/gal = $70,000/year
Annual Fuel Savings: $50,000+
Financial Incentives
Federal Incentives
Vehicle Tax Credits:
- Up to $7,500 per vehicle (income limits don't apply to businesses)
- Commercial Clean Vehicle Credit (no MSRP cap for businesses)
Infrastructure Credits:
- 30% of installation costs (Alternative Fuel Vehicle Refueling Property Credit)
- Up to $100,000 per location for commercial
State and Local Incentives
Examples:
- California: HVIP vouchers up to $45,000/vehicle for commercial
- Colorado: $5,000/vehicle commercial credit
- New York: Truck Voucher Incentive Program
Utility Programs:
- Demand response incentives
- Off-peak charging rates
- Make-ready programs (utility pays for some infrastructure)
Check: AFDC (Alternative Fuels Data Center) for current incentives in your state.
Operational Best Practices
Smart Charging
Load Management:
- Stagger charging to reduce peak demand
- Prioritize vehicles needed soonest
- Respond to utility demand signals
Demand Charges:
- Commercial electricity often has demand charges
- Spread charging to minimize peak demand
- Consider battery storage to buffer peaks
Driver Training
Key Topics:
- How to plug in correctly
- Understanding range and efficiency
- What to do if charge isn't working
- Emergency procedures
Vehicle-Charger Assignment
Strategies:
- Assigned spots (simplest)
- First-come-first-served (more flexible)
- Software-managed rotation (optimal utilization)
Monitoring and Reporting
Track:
- Energy consumption per vehicle
- Charging session data
- Costs and savings vs baseline
- Vehicle availability/uptime
Common Fleet Challenges
Challenge: Not Enough Electrical Capacity
Solutions:
- Smart charging to reduce peak demand
- Phased rollout
- Battery storage systems
- Utility make-ready programs
Challenge: Vehicles Need More Range
Solutions:
- En-route DC fast charging network cards
- Larger battery vehicles for high-mileage routes
- Mixed fleet (EVs for appropriate routes)
Challenge: Driver Resistance
Solutions:
- Comprehensive training
- Showcase early adopter successes
- Address concerns directly
- Highlight driver benefits (smoother, quieter)
Challenge: Upfront Costs
Solutions:
- Maximize incentives (federal, state, utility)
- Phased implementation
- Charging-as-a-service (avoid upfront infra cost)
- TCO analysis showing payback period
Case Study: Delivery Fleet
Company: Regional delivery service
Fleet Size: 30 vehicles
Daily Mileage: 80-120 miles per vehicle
Solution:
- 20 Level 2 chargers at depot
- Smart charging software
- 3-year vehicle transition plan
Results:
- Fuel savings: $65,000/year
- Maintenance savings: $22,000/year
- Infrastructure cost: $85,000 (after incentives)
- Payback: 1 year
Getting Started
Phase 1: Pilot (3-6 months)
- Select 3-5 vehicles for pilot
- Install 2-3 chargers
- Gather real-world data
- Identify challenges
Phase 2: Planning (1-3 months)
- Analyze pilot results
- Design full infrastructure
- Secure incentives/financing
- Create implementation timeline
Phase 3: Rollout (6-18 months)
- Install infrastructure in phases
- Transition vehicles progressively
- Train drivers
- Optimize operations
Conclusion
Fleet electrification is increasingly compelling financially and operationally. Success requires:
- Assess your needs - Understand daily mileage and parking patterns
- Right-size infrastructure - Start with depot Level 2 for most fleets
- Leverage incentives - Federal, state, and utility programs significantly reduce costs
- Implement smartly - Load management, driver training, monitoring
- Start now - Pilot programs derisk and accelerate full deployment
The companies that electrify their fleets today will have significant cost and competitive advantages in the years ahead.
Use ChargeFind to explore public charging options that supplement your depot infrastructure and support drivers on longer routes.