Depot charging planning for fleets: reduce TCO and meet CVD quotas
Your fleet electrification starts not with the vehicle, but with intelligent depot charging planning.
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The topic briefly and concisely
A data-driven analysis of driving profiles and dwell times is the basis for any cost-effective depot charging strategy for a fleet.
For overnight depot charging, 22 kW AC charging stations are the TCO-optimal and most battery-friendly solution in over 90% of cases.
Intelligent load management is essential to avoid costly peak loads and make optimum use of the existing grid connection.
Transitioning to electric commercial vehicles presents fleet managers with complex challenges that go far beyond vehicle selection. A key pillar of success is depot charging planning for the fleet. Without tailored charging infrastructure at your own site, efficiency gains remain untapped and operating costs stay unnecessarily high. Professional analysis and planning not only secures daily operational readiness for up to 100% of your vehicles, but is also the most economical way to meet the statutory requirements of the Clean Vehicles Directive. This guide sets out the key steps towards the optimal charging infrastructure.
Phase 1: Data-driven fleet analysis as the foundation
A successful depot charging plan for your fleet starts with an analysis of the current situation. This data foundation prevents poor investment in over- or under-capacity. A typical analysis records the operating schedules of at least 95% of all vehicles.
First, the vehicle types and their energy requirements are recorded. A HEERO with a 137-kWh battery has different charging requirements than smaller vehicles. The average overnight dwell times are the most important factor, because they define the primary charging window of often 8 to 10 hours.
The analysis of driving profiles provides crucial data. We review the daily kilometres driven across the entire HEERO fleet in use at our customers' sites in order to determine actual energy consumption. This shows that for 80% of fleets in the last-mile sector, overnight AC charging is entirely sufficient. Such data-driven strategic fleet electrification lays the foundation for correctly sizing the infrastructure.
Phase 2: Correctly sizing the charging infrastructure
Based on the analysis results, the technical design of the charging infrastructure is carried out. The key decision lies between AC and DC charging systems. For depot charging, AC charging at 22 kW is the most economically sensible solution in over 90% of use cases.
The reasons for this are purely pragmatic:
Lower investment costs: AC wallboxes are up to 10 times cheaper to purchase than DC fast-charging stations.
Protecting the vehicle battery: Slower charging over several hours significantly maximises the service life of the 137 kWh batteries.
Reduced grid connection costs: A charging output of 22 kW per vehicle is easier to integrate into existing grid connections.
Optimal use of downtime: Vehicles are often parked in the depot for more than 8 hours and can therefore be fully charged cost-effectively.
A HEERO requires around 6 hours for a full charge at a 22 kW wallbox. This charging duration fits perfectly into the overnight depot window. Planning must also take future growth into account. Scalability of the system within the first 3 years is a typical approach. The right AC charging infrastructure is therefore a key lever for reducing TCO.
Phase 3: Intelligent load management for cost control
If many electric vehicles are charged at the same time, the power peak can overload the grid connection. Intelligent load management is therefore not an optional extra, but a commercial necessity. It prevents costly load peaks that can noticeably, or even significantly, increase the electricity bill.
Dynamic load management intelligently distributes the available total power of the grid connection across all charging vehicles. It takes account of the charge status of the individual batteries and prioritises vehicles that need to depart earlier the next morning or start with a fuller battery. This ensures that the fleet starts the day with 100% operational readiness, without having to expand the grid connection for tens of thousands of euros.
Savings of up to €15,000 per year from avoided load peaks alone are realistic for a fleet of 20 vehicles. Integration with a photovoltaic system can further reduce operating costs by maximising self-consumption. A well-thought-out load management concept is the core of efficient depot charging planning for any fleet.
Phase 4: Ensuring TCO optimisation and CVD compliance
The strategic depot charging planning of your fleet is the greatest lever for reducing total cost of ownership (TCO). Lower „fuel costs“ due to cheaper night-time electricity or PV electricity significantly reduce the variable costs per kilometre compared with a diesel Sprinter. There are also reduced maintenance costs of around 40% for electric vehicles.
At the same time, electrification ensures compliance with the Clean Vehicles Directive (CVD). The initial procurement quotas for light commercial vehicles of 38.5% in 2025 were a clear requirement. This will be tightened further in the following years. A HEERO enables a faster transition. This means fleet operators can meet their CVD quotas faster and more economically.
The combination of the HEERO eDrive system and optimised depot charging can significantly reduce TCO over a holding period of 5 years. Planning the charging infrastructure is therefore a direct investment in the future viability and profitability of the entire fleet. Professional advice on depot charging is the first step.
More useful links
PwC offers an accompanying study on promoting electric buses in local public transport.
BWVL publishes an article on the decarbonisation of road freight transport and criticises mandatory ZEV quotas.
WBO provides a feasibility study on the Clean Vehicle Directive (CVD).
The portal Deutsche eVergabe offers detailed information on the Clean Vehicle Directive (CVD) and clean vehicles.
Fraunhofer ISI provides information in a press release about fast-charging stations for electric trucks in Europe.
Bundesnetzagentur provides comprehensive information on electric mobility.
NOW GmbH offers a practical guide to electric mobility in fleets.
Agora Verkehrswende publishes a factsheet on municipal e-fleets.
KPMG Law examines the legal challenges of electric mobility in logistics.
FAQ
How many charging points do I need for my fleet?
The number does not depend on the size of the fleet, but on the simultaneous charging requirements. An analysis of the duty schedules shows how many vehicles really need to be charged overnight at the same time. Often, a ratio of one charging point for two to three electric vehicles is sufficient, if intelligent load management and fixed allocations are used.
Is my current power connection sufficient for charging the fleet?
A certified electrical contractor must assess this. However, intelligent, dynamic load management can distribute the available power so efficiently that an expensive upgrade to the grid connection can often be avoided. It protects the grid from overload and cuts costly peak loads, significantly reducing electricity costs.
Is fast DC charging at the depot not better?
Not necessarily. DC charging is expensive to purchase, install and maintain. Since the vehicles typically remain in the depot for 8–10 hours, the slower and more cost-effective 22 kW AC charging is usually the more economical and battery-friendly solution. DC charging only makes sense if vehicles also need to be back in service quickly during the working day.
What happens if there is not enough electricity for all vehicles?
A professional load management system prevents this scenario. It prioritises charging processes based on the state of charge (SoC) and the planned departure time of each vehicle. This ensures that by the next morning all vehicles have reached the energy level required for their route, even if not all are charged to 100%.
Can I also invoice the charging electricity when employees charge privately?
Yes, a modern charging infrastructure includes a backend system that enables precise recording and billing of all charging sessions. Using RFID cards or apps, charging sessions can be assigned to individual users (e.g. company car, pool vehicle, private vehicle) and billed in line with metering regulations. This ensures full transparency and cost control.
How long does it take to plan and implement a charging infrastructure?
The duration varies depending on project size and complexity. An initial analysis and concept development can be completed within 2–4 weeks. Coordination with the grid operator and the actual installation by specialist contractors typically take a further 8–16 weeks. Early planning is crucial to avoid bottlenecks.
