The Warehouse Logistics Challenge

A mid-size e-commerce distribution centre handling 50,000 parcels per day operates a complex vehicle fleet: yard trucks moving trailers between docks and storage areas, delivery vans dispatching last-mile deliveries, staff transport vehicles and maintenance equipment. Diesel vehicles generate emissions inside and around the facility, creating air quality issues for workers. Rising fuel costs and driver shortages are increasing operating costs. Regulatory pressure to reduce emissions is intensifying.

Operational Scenario: E-Commerce Distribution Centre

Consider a distribution centre with 20,000 m² of floor space, 50 loading docks and a daily dispatch of 50,000 parcels. The vehicle fleet includes:

• 30 last-mile delivery vans (urban routes, 80–120 km/day each)
• 8 yard trucks (dock-to-dock movements, 40–60 km/day each)
• 4 staff shuttle vehicles (car park to facility): 30–50 km/day
• 3 autonomous delivery vehicles for local micro-fulfilment routes
• 6 maintenance and facilities vehicles: 20–40 km/day

Electrifying the Delivery Van Fleet

The 30 last-mile delivery vans are the highest-priority electrification target. Urban routes of 80–120 km/day are well within EV range. Overnight depot charging at 7–22 kW AC is sufficient for full recharge. Energy cost savings of 65–70% per van reduce operating costs significantly. The vans operate in urban low-emission zones — electric vans avoid access restrictions and potential fines that diesel vans face.

Autonomous Vehicles for Micro-Fulfilment

The distribution centre deploys 3 autonomous delivery vehicles (ADVs) for a micro-fulfilment pilot — delivering parcels to a cluster of residential buildings within 2 km of the facility. The ADVs operate on defined routes, collecting parcels from a dispatch station at the facility and delivering to building reception points. The pilot reduces the number of van trips required for the micro-fulfilment zone by 40%, freeing van capacity for longer routes.

Charging Infrastructure

The facility installs 35 AC charging points (22 kW) in the van depot and 4 DC fast chargers (150 kW) for rapid turnaround charging during operational breaks. A load management system manages the grid connection and prevents peak demand charges. The total infrastructure investment is approximately €280,000. Solar panels on the warehouse roof generate approximately 400 kWh/day, covering approximately 25% of charging energy.

Worker Environment and Safety

Electric vehicles significantly improve the working environment inside and around the distribution centre. No diesel exhaust fumes in the loading dock area improves air quality for workers. Reduced noise from electric yard trucks and vans improves the acoustic environment. Lower maintenance requirements reduce the time vehicles spend in the workshop, improving fleet availability. Worker satisfaction with the improved environment is a measurable benefit.

Operational Results (Projected)

Based on typical distribution centre fleet electrification outcomes:

• Energy cost saving: 65% reduction in fuel costs for delivery vans
• Maintenance saving: 35% reduction over 5 years
• CO₂ reduction: 80% reduction in direct fleet emissions
• ADV micro-fulfilment: 40% reduction in van trips for micro-fulfilment zone
• Low-emission zone compliance: full access to urban delivery zones
• Payback period: 3–4 years for delivery vans; 2–3 years for ADV programme