Solving the depot charging challenge in last-mile logistics

As last-mile logistics companies accelerate their transition to electric fleets, much of the focus tends to be on vehicle selection—comparing range, payload, and cost. However, an often-overlooked factor is charging infrastructure, which is just as critical to ensuring smooth operations.

In this blog post, we explore why depot charging is essential for last-mile logistics, the key challenges businesses face in managing it, and the strategies that ensure a reliable, scalable, and cost-effective charging setup.

The overlooked importance of depot charging

Without a well-planned and properly managed depot charging setup, fleets risk inefficiencies, unexpected downtime, and increased operational costs. Charging strategies must align with real-world fleet requirements — when vehicles need to charge, how long they remain idle, and how many chargers are available per shift. A misalignment in any of these areas can lead to bottlenecks, vehicle unavailability, and ultimately, service delays.

For last-mile logistics, where on-time deliveries are crucial, charging infrastructure is not just a supporting element—it is the backbone of a successful EV fleet strategy.

Strategic planning for depot charging: aligning with business operations

A successful depot charging strategy isn’t just about installing chargers — it’s about ensuring they seamlessly support fleet operations. To optimize efficiency and minimize downtime, companies must assess their operational model and tailor their charging infrastructure accordingly.

Key factors to consider include:

• The number of chargers needed to support the fleet’s daily energy requirements.
• Power levels and charger types — fast chargers for quick top-ups or slower, cost-efficient overnight charging.
• Charging schedules — whether vehicles will primarily charge overnight or require mid-shift top-ups.

Different last-mile delivery models demand different charging approaches:

• Same-day delivery fleets face fluctuating demand, which can change not just daily but throughout the day. At times, a quick top-up is necessary to keep operations running smoothly. Having a high-power DC fast charger at the depot ensures vehicles can recharge efficiently without long downtimes.
• Parcel delivery fleets with fixed routes may have the flexibility to rely on overnight charging, reducing the need for expensive daytime charging infrastructure.

Ultimately, a flexible and scalable depot charging setup is key to ensuring business continuity and long-term fleet efficiency. Without strategic planning, companies risk underutilizing their infrastructure or, worse, experiencing bottlenecks that disrupt daily operations.

Operational challenges of managing depot chargers

Even with a well-planned charging strategy, managing depot chargers comes with its own set of operational challenges. Charger downtime can be unpredictable, and without proper contingency plans, fleet operations can quickly be disrupted.

• Technical failures can happen at any time, whether due to hardware malfunctions, software bugs, or power supply issues.
• Some issues can be resolved remotely using a charge point management system (CPMS), minimizing downtime.
• However, more complex failures require on-site maintenance, which can take days or even weeks—potentially impacting fleet availability.

When chargers go offline, the effects ripple through fleet operations:

• Vehicles may not be fully charged in time for their next route, leading to delivery delays.
• With a limited number of chargers, breakdowns create bottlenecks in the charging schedule, affecting fleet rotation.
• Public charging is not a reliable backup, as it comes with higher costs and uncertain availability.

This creates a scalability vs. reliability dilemma for fleet operators:

• Installing one charger per vehicle guarantees availability but significantly increases infrastructure costs. (However, if one or more chargers break down, fleet operators may still face charger allocation challenges.)
• Using fewer chargers than vehicles is cost-effective but requires a well-optimized charging rotation plan to avoid bottlenecks and downtime.

Balancing cost, availability, and operational efficiency is key to ensuring that depot charging remains reliable and scalable as fleets grow—but to truly minimize risks, companies need proactive prevention and contingency strategies.

Mitigating charging risks: prevention and contingency strategies

Even with a well-optimized charging setup, unexpected failures can still occur. To maintain seamless operations, last-mile logistics companies need both proactive prevention measures and tactical response strategies when things go wrong.

Proactive strategies to minimize charging disruptions

• Keep vehicles at a high state of charge (SoC) when possible
  • Maintaining a buffer charge ensures flexibility if a charger unexpectedly goes offline.
  • Reduces reliance on last-minute charging, preventing operational delays.
• Consider some chargers as an extra ‘buffer’
  • Keeping a small percentage of chargers as spares can prevent disruptions when failures occur. This doesn’t mean installing more chargers than vehicles; rather, an optimized charging schedule can help ensure efficient use of available infrastructure.
  • These backup chargers help absorb demand spikes and reduce downtime risks.
• Remote monitoring and preventive maintenance
  • Utilizing a charge point management system (CPMS) enables real-time tracking of charger performance.
  • Identifying and resolving minor issues early helps prevent full breakdowns that could impact fleet operations.

Tactical responses when a charger fails

• Reallocate vehicles to available chargers
  • Identify underutilized or available chargers within the depot.
  • Adjust charging priority based on route urgency to ensure critical deliveries remain on schedule.
• Adjust charging schedule to reduce overlap
  • Stagger charging times to prevent bottlenecks and avoid congestion at peak hours.
  • Prioritize essential fleet vehicles to ensure they are fully charged for their next shift.
• Public charging as a last resort
  • While expensive and often unreliable, public charging can provide emergency top-ups when no depot chargers are available.
  • Fleet managers should have a contingency plan for accessing nearby charging stations in case of unexpected charger failures.

By combining preventive planning with agile response strategies, companies can minimize the impact of charging disruptions and keep their last-mile delivery operations running smoothly — even when challenges arise.

How Volteum helps optimize depot charging

Charging infrastructure is not just a capital investment — it is a core operational component of last-mile logistics. Proper planning, proactive maintenance, and contingency strategies are essential to ensure fleet uptime and avoid costly disruptions. By treating depot chargers as critical assets and optimizing their management, companies can improve efficiency, reduce costs, and ensure seamless operations.

At Volteum, we help last-mile fleets solve these challenges with intelligent charging management solutions. Our Charging Schedule Optimization feature ensures vehicles are charged at the right time, maximizing uptime while minimizing costs. By automating schedules and optimizing charger usage, we make depot charging efficient, scalable, and easy to manage.

Ready to improve your fleet’s charging operations? Contact us today to learn how Volteum can help.