By Paul Barringer, head of EV charging UK & Ireland at renewable energy technology firm Sungrow.

Paul Barringer, head of EVC UK and Ireland at Sungrow

As the UK accelerates toward its ambitious 2030 phase-out of internal combustion engines for cars and vans, and the complete transition to zero-emission vehicles by 2035, fleet operators are under pressure to electrify.  Yet while that provides a lot of opportunities, electrifying commercial fleets presents distinct operational, technical and economic demands that often exceed the capability of consumer EV charging solutions. So, what are they and just what solutions exist in the energy storage system (ESS) and EV charging world to solve them?

What sets consumer and commercial apart – grid constraints and power bottlenecks

Commercial vehicles demand significantly higher power levels than consumer cars.  While consumer electric cars typically charge with 11 to 22kW for AC charging or up to 150kW for DC fast charging on the road; commercial vehicles require charging power of several hundred of kilowatts, particularly for long-distance transport or intermediate charging during extended journeys.

The need for high-power and faster-charging is greatly impacted by location. Installation of appropriate infrastructure can require complex permitting and grid connection processes. Similarly, in some European markets, grid capacity constraints have already become critical bottlenecks. The Netherlands, for example, faces grid capacity limitations that make connecting new charging stations virtually impossible in many locations. Many fleet journeys are regional in nature, often covering relatively short distances, suggesting that targeted expansion of charging infrastructure at logistics locations could have rapid impact. However, the necessary grid reinforcement remains both technically and economically complex and highlights the need for innovative solutions that work within the constraints of existing infrastructure.

Alongside challenges related to infrastructure, commercial fleet charging must also integrate seamlessly into existing operations. Fleet vehicles are often in near continuous use, with very limited charging windows that must be precisely coordinated with rest periods, route planning and logistics processes. Any vehicle downtime creates disruption to supply chains, customer satisfaction and contractual obligations. To achieve this level of integration, companies need advanced software solutions that can manage multiple variables in real time while maintaining operational efficiency. Every minute of downtime directly impacts productivity and profitability, with charging downtime potentially costing fleets up to eight times more than the electricity itself and equating to around 260 non-productive hours annually while vehicles are ‘on shift’.

All of the above are considerations that any consumer electric car owner would likely never have to worry about. This means investing in charging systems that can deliver the charging speeds fleet operations demand, and not settling for scaled-up consumer solutions.

Technological fixes for technical problems

Technology providers are developing various systems and solutions to tackle these issues head on. The most promising approach for fleet electrification involves comprehensive depot solutions that combine photovoltaic (PV) systems, battery storage and DC charging technology tailored to local operational processes. These ‘comprehensive packages’ enable fleets to efficiently convert to electricity while incorporating self-generated power and grid-friendly infrastructure.

One innovative way this is being achieved is hybrid charging systems, which combine onsite solar power with battery storage. These systems store energy when demand is low and release it during peak charging times, helping to balance loads and reduce reliance on limited grid capacity. Combined with fast DC chargers, these hybrid systems create scalable systems with lower operating costs while reducing demand on the grid.

The focus on depot solutions reflects the reality that fleet electrification requires close collaboration between technology providers and fleet operators. Direct communication with future users is essential to enable adaptations to specific operational processes and ensure flexible project implementation

Beside compact chargers, one potential way to execute this lies in satellite-based charging systems, which have emerged as a potential game-changer. These systems utilise a central power unit with approximately one megawatt of power to supply several decentralised charging points. This approach intelligently distributes charging power, with each satellite able to be flexibly positioned onsite, allowing for multi-vehicle charging based on demand, facilitating site planning and allowing fleet owners to optimise both investment and running costs.

AI – Giving charging a cutting edge

We’d be remiss if we didn’t discuss how artificial intelligence (AI) is increasingly being deployed to help efficiently manage operations and maintenance of charging infrastructure. As you’ll know, regular charging infrastructure failures cannot be tolerated; operations depend on absolute reliability to meet delivery schedules and contractual obligation.

What we’ve seen in the industry is the implementation of AI-supported systems that continuously analyse the condition of charging technology, detecting early signs of component wear or malfunctions to allow for predictive maintenance planning. The software also enables automatic error prediction, immediately notifying responsible technicians when technical problems occur or are imminent, improving response times and ensuring greater operational reliability. This ultimately reduces downtime and maintains stable operations.

For fleet operations, this approach transforms charging infrastructure from a necessary cost into a strategic asset that supports rather than hinders operations.

Invest to make fleet charging a success

As fleet electrification accelerates, the constraints we see in the grid and infrastructure may become increasingly apparent. To combat this, fleet operators should opt for high-performance systems – charging infrastructure that can think ahead, are scalable, robust and economically viable, and can actively support fleet operations rather than simply providing power.

Fortunately, the incorporation of hybrid charging, centrally controlled satellite systems and AI powered systems for control and maintenance can meet all these requirements. Those who invest early in well-thought-out charging infrastructure that not only supplies energy but integrates seamlessly with operational demands will be best positioned to lead the transition to electric fleets, delivering benefits for both business performance and climate goals.