When electrifying a fleet, one key question arises: How many charging points are really needed – and at what power level? Instead of planning a demand-oriented charging infrastructure, many companies take the “maximum strategy”: Better too many charging stations than too few.
Why wrong charging infrastructure planning gets expensive
In fleet electrification, many companies invest prematurely in additional charging points without analysing their actual needs. Often, high-powered DC fast chargers are installed, only to remain underutilised, while other critical locations lack sufficient charging capacity.
The result: high infrastructure costs, low utilisation rates, and unnecessary operating expenses.
This is how the overdimensioning cost trap emerges – a common mistake that drives up charging infrastructure costs and undermines the profitability of an electric fleet.
Typical consequences of overdimensioning
A miscalculated charging infrastructure not only strains budgets but also slows down operations.
- Overinvestment in EV charging: Charging points are only used at 10–20% of their capacity in daily operations.
- Wrong priorities: Some sites lack chargers while expensive units sit idle elsewhere.
- High follow-up costs: Maintenance and servicing for oversized DC charging technology add up to five-figure amounts every year.
Where the problem starts
Why do companies fall into this trap? Because charging infrastructure planning is often based on assumptions rather than data.
- Range optimism: Calculations rely on manufacturer specifications instead of real driving profiles.
- Neglecting real-world factors: Winter operation, battery degradation, and heavy payloads significantly increase energy demand.
- Fascination with fast charging: Costly DC chargers are installed where affordable AC charging would be sufficient.
How to avoid costly charging mistakes
The solution lies in demand-driven charging infrastructure planning: data instead of gut feeling, scalability instead of overdimensioning.
Companies that align their charging points with actual fleet needs not only save on infrastructure investments but also increase the efficiency and availability of their electric fleet.
Which steps are crucial – from driving profile analysis to modular charging infrastructure – you will learn in our free e-mail course “Your roadmap to successful fleet electrification”.
More from the series “The 5 biggest mistakes in fleet electrification”
- Grid capacity trap – the most expensive mistake in fleet electrification
- All-charging-at-once myth – why your charging infrastructure is overloaded
- 1:1 replacement myth – why diesel vehicles cannot simply be swapped one-to-one
- Data silo blockade – how missing data integration slows down your EV fleet
Your roadmap to successful fleet electrification
