The transition to electric Heavy-Duty Vehicles (HDVs) is a top priority for commercial fleets as regulations tighten and zero-emission targets become embedded in corporate agendas. For example, the European Union (EU) set a goal for a 90% reduction in truck emissions by 2040. In North America, industry trend-setters Walmart and PepsiCo are committed to fully electrifying their trucking fleets by that same timeline, although there are doubts about viability. To comply with these regulations and successfully transition to an electric future, supply chain operators must now develop and execute a comprehensive fleet electrification plan. Using my consulting experience within the automotive/Electric Vehicle (EV) industry, I will share four tips to craft a blueprint.
1. Match Charging Infrastructure to Fleet Duty Cycles
The starting point for a fleet electrification plan is understanding where and how your vehicles operate. This is because charging needs vary by route type. Mapping fleet duty cycles to the right charging method ensures that the charging infrastructure supports daily vehicle use without impacting delivery windows.
For short-range or regional fleet use cases, depot charging is typically adequate. Trucks like the Volvo FH Aero Electric can recharge overnight at a depot using a 43-Kilowatt (kW) Combined Charging System (CCS) charger, providing up to 300 Kilometers (km) of range. This alone is enough for a significant portion of daily fleet operations.
For longer routes, fleet managers should consider en-route charging via Megawatt Charging Systems (MCSs). This charging technology is capable of delivering over 500 km of range in less than an hour, which aligns well with regulated driver break times.
Sometimes truck drivers find themselves in a middle ground, where they drive too far for a single charge, but consistently stop at the same locations. In this case, destination charging is a good option. Destination charging is an opportunistic technique, whereby charging infrastructure is installed at distribution centers or warehouses. That way, Electric Trucks (eTrucks) can be charged during the loading or unloading process at logistical hubs.
Depot charging dominates HDV charger shipments due to its reliance on simple overnight, low-power charging, making it ideal for initial electrification of short daily routes under 200 km. Depot charging is also relatively cheap, enabling fleets to take advantage of off-peak charging times.
Adoption of heavy-duty chargers is expected to increase in 2029 with MCS chargers improving long-term costs and regulatory pressures, though longer journeys will drive the need for high-power, en-route public charging. While MCS certification will officially be introduced in 2026, the time lag is due to geopolitical considerations and an adjustment period as stakeholders retrofit existing sites with MCS chargers.
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2. Purchase Vehicles with Charger Compatibility
Vehicle charging compatibility is another essential factor in a fleet electrification plan. Your eTrucks need to be compatible with the chargers you’re using or planning to install. Most heavy-duty EVs built for the MCS standard will include MCS and CCS sockets to handle different charging needs:
- MCS provides fast en-route charging with up to 1.5 Megawatts (MW) of power in practical use, ideal for quick stops on long hauls.
- CCS, on the other hand, supports slower overnight depot charging with either Alternating Current (AC) or Direct Current (DC) power, fitting well for downtime at a base location.
This dual-socket approach empowers you to tap into the widespread CCS charging network today, while preparing for the MCS chargers of tomorrow. A CCS plug won’t fit an MCS socket and the reverse holds true due to their distinct designs, so having both ensures that your fleet isn’t limited by infrastructure.
In cases where vehicles rarely require slow charging, a commercial trucking fleet benefits from an MCS-only setup. Skipping the onboard charger could lower weight and cost for those specific routes. Yet, my research indicates that an MCS-only setup is usually outweighed by the advantages of dual sockets, namely better resale value and access to widespread CCS chargers. Unless your operations are narrowly focused, planning for dual-socket HDVs keeps your fleet electrification strategy adaptable as MCS charging infrastructure gradually expands over time.
3. Choose Partners Who Can Provide Reliability
Charger reliability is critical for vehicle uptime. If a charge point fails or if there is insufficient grid capacity, deliveries can be delayed and customers will be upset. For these reasons, fleet operators must plan to partner with Charge Point Operators (CPOs) and equipment suppliers who take the following actions:
- Ensure Sufficient Grid Capacity: This will enable CPOs to handle peak electricity demand. You can’t afford to be short when every truck rolls in at once.
- Prioritize Connectivity: Reliable cellular coverage, or Wi-Fi and Ethernet backups, keeps chargers linked to your systems.
- Account for Weather Impacts: Snow can clog connectors and heat can fry components, so tailor maintenance plans to each site.
- Provide Robust Services: Select Electric Vehicle Supply Equipment (EVSE) providers that guarantee fleet uptime, offer preventative maintenance like replacing worn cables, and send emergency response teams quickly when remote fixes fail.
- Use a Robust Charging Management System: It spots charging faults early, preventing escalation and keeping your fleet moving.
4. Integrate Charging Schedules with Fleet Operations
Often, an EV driver pulls up to a charge station only to discover it’s not currently drawing enough electricity to power the rest of a trip. To avoid this scenario, commercial fleet operators must coordinate with CPOs to ensure that charging availability aligns with fleet schedules. Failing to do so will inevitably lead to delays and disappointed customers.
Time slot reservations, supported by smart charging systems and in-vehicle navigation, will be key to optimizing supply chain routes based on grid capacity. For example, a long-haul driver could time their mandatory break when they know a 1.5-MW charger will be open.
The Road to Fleet Electrification Requires a Calculated Approach
An effective fleet electrification plan includes thoughtful consideration of charging methods, reliability, scheduling, grid readiness, and vehicle compatibility. Starting with depot-based solutions can electrify a large portion of urban and regional operations. However, many long-haul trucking use cases require more robust MCS chargers that have yet to be built at scale.
The commercial fleet industry does not benefit from enthusiasts, as the consumer EV market does. Supply chain leaders will always think from a business standpoint first, making cost and convenience deciding factors in determining when to switch their trucks to fully electric powertrains. By addressing all aspects of the transition—planning, infrastructure, vehicles, and operations—organizations can stay ahead of regulations and lead the shift toward a cleaner transportation future. Additionally, organizations must begin exploring the market landscape to identify potential partners that can facilitate the electric transformation of fleets.
CPOs like Milence and EVSE vendors like Siemens are already expanding high-speed charging networks, making it easier to scale up in the coming years. Milence is the only CPO offering Direct Current Fast Charging (DCFC) for en-route charging and plans to provide 2,000 to 3,000 of the 20,000 fast chargers that Europe is expected to need by 2030. Similarly, Siemens’ acquisition of Heliox will bolster its DCFC portfolio for eTruck and eBus fleets. The company’s eMobility solutions will now range from 40 kW to 1 MW of charging for depot and en-route charging. Without collaboration with innovative leaders like these two firms, an electric future for commercial fleets is impossible.
For further consultation on how to successfully plan your fleet electrification journey and gauge the market’s future outlook, explore our latest electrification report and forecasts: