Range: Real-World Expectations
Range is the most frequently cited concern when evaluating electric vans. Modern electric light commercial vehicles offer 150–350 km of real-world range depending on payload, speed, temperature and auxiliary loads. For urban and suburban operations — the majority of commercial van use — this is more than sufficient. The average urban delivery van covers 80–120 km per day. Range becomes a constraint only for long-distance or rural operations.
- Average urban delivery van: 80–120 km per day — well within EV range
- Suburban and regional routes: 120–200 km per day — manageable with overnight charging
- Long-distance and rural routes: may require route planning or DC top-up charging
- Cold weather: range can reduce by 15–25% in temperatures below 0°C
- Payload impact: heavier loads reduce range — factor in typical payload when assessing range
Payload and Cargo Capacity
Electric vans carry battery packs that add weight — typically 200–400 kg compared to a diesel equivalent. This reduces the available payload. For operators with weight-sensitive loads, this is a real consideration. However, for most urban delivery operations, the actual payload carried is well below the vehicle's maximum — meaning the battery weight penalty has no practical impact on operations.
Running Costs: Fuel vs Electricity
The running cost advantage of electric vans is significant. Electricity costs per kilometre are typically 60–75% lower than diesel, depending on energy prices and charging method. For a van covering 30,000 km per year, this represents a substantial annual saving.
| Factor | Electric Van | Diesel Van |
|---|---|---|
| Energy cost per 100 km | €2–4 (AC depot) | €8–14 (diesel) |
| Annual fuel/energy cost (30,000 km) | €600–1,200 | €2,400–4,200 |
| Annual saving (electric vs diesel) | €1,800–3,000 | — |
| Oil changes | None | 2–3 per year |
| Brake replacement frequency | Reduced (regen braking) | Standard |
| Drivetrain service intervals | Extended | Standard |
Maintenance Costs
Electric vans have significantly lower maintenance costs than diesel equivalents. There is no engine oil, no timing belt, no exhaust system, no diesel particulate filter and no complex transmission to service. Regenerative braking reduces brake wear. Fleet operators typically report 30–50% lower maintenance costs for electric vans compared to diesel equivalents over a 5-year period.
Total Cost of Ownership (TCO)
The higher purchase price of electric vans is the primary barrier to adoption. However, when running costs and maintenance savings are factored in over a 5–7 year ownership period, the total cost of ownership of electric vans is increasingly competitive — and in many urban fleet applications, already lower than diesel.
Operational Fit: When Electric Wins
Electric vans are the clear choice for urban and suburban operations with predictable daily routes, overnight depot charging and daily distances under 200 km. They are also advantageous for operators in or near low-emission zones, for noise-sensitive delivery areas and for organisations with sustainability commitments. Diesel remains more practical for long-distance, rural or unpredictable-route operations where charging infrastructure is limited.
Charging Infrastructure Requirements
Transitioning to electric vans requires depot charging infrastructure. A standard 7 kW AC wallbox per vehicle is sufficient for overnight charging in most cases. For larger fleets or faster turnaround requirements, 22 kW AC or DC fast charging may be appropriate. The cost of depot charging infrastructure — typically €1,000–3,000 per charging point installed — should be factored into the TCO calculation.
Key Takeaways
- 1Electric vans cost 60–75% less per km to run than diesel
- 2Maintenance costs are 30–50% lower over a 5-year period
- 3Average urban van covers 80–120 km/day — well within EV range
- 4Battery weight reduces payload by 200–400 kg — rarely a practical constraint
- 5TCO is increasingly competitive for urban fleet operations
- 6Depot charging infrastructure is required — budget €1,000–3,000 per point
Summary
Electric vans offer 60–75% lower energy costs, 30–50% lower maintenance costs and zero local emissions compared to diesel. For urban and suburban operations with overnight depot charging, the total cost of ownership is increasingly competitive. Range, payload weight penalty and upfront cost remain considerations — but for most urban fleet applications, the case for electric is now compelling.