As state and federal regulatory mandates pressure the freight and logistics industry to decarbonize — and as expectations from both companies and customers highlight the importance of greater sustainability — there is no question that supply chain organizations must be positioned to respond to these demands in order to keep their businesses moving forward. Supply chains account for approximately 60% of all global carbon emissions (and 28% of greenhouse emissions in the U.S. alone), making it imperative that companies work toward practical decarbonization to reduce the environmental impact on a mass scale.
Electrification is likely the most obvious solution, particularly for freight carriers. However, the upfront costs associated with adopting an electric fleet and building the infrastructure needed in order to keep each EV charged and on the road is cost-prohibitive for most companies.
In order to provide carriers with a practical and scalable alternative to fleet electrification, Range Energy has introduced its hybrid eTrailer System that is designed to help companies meet the call for greater sustainability and comply with federal and state regulations without requiring significant infrastructure investments.
As Demand for Fleet Electrification Grows, Infrastructure Falls Short
A number of upfront considerations must be made in order to make fleet electrification a reality, and when combined with long implementation timelines, these challenges make it difficult for fleets seeking to electrify their tractors.
High Cost of Charging Infrastructure
The costs associated with shifting from diesel tractors to EV units present the first financial hurdle for many companies when it comes to overall fleet electrification, as a single EV unit can exceed the cost of a traditional diesel tractor by $200,000-$300,000. However, infrastructure requirements for charging EV tractors also quickly compound, with the cost to install a single DC fast charger ranging from $70,000 to $130,000 per unit, according to the ICF.
Additional financial considerations must be made around the electrical systems that support the charging stations as well, as EV tractors require much higher power charging in order to be able to replenish the batteries in a reasonable amount of time and prevent excessive downtime. As a result, the site’s electrical service itself must often be updated in order to be able to supply the amount of power needed for timely charging, particularly for DC fast chargers. Current parking and maintenance facilities may also need to be retrofitted in order to support EV tractors.
Add to this the costs of any additional repairs and required maintenance, and a full EV transition simply becomes out of the question for many carriers.
Limited Availability of Charging Stations
Charging is another key consideration that can quickly deter fleets from electrification if access to charging stations is not available when needed. For example, when traveling through rural areas, charging infrastructure may not yet be implemented and could leave drivers stranded if they aren’t able to find a charger before their battery becomes depleted. For congested regions, drivers may also face long wait times and additional downtime that could impact delivery timelines and delay shipments. Having limited access to charging in certain areas can also create logistical and routing challenges, particularly for long-haul fleets.
Added concerns around delays at public charging locations — as well as proprietary networks that may prevent access or require adapters or specialized equipment in order to use them — can also limit flexibility and further deter fleets from full electrification. Although charging networks are expanding to help ease these concerns, issues like delays in getting permits for added chargers will slow the process of further building out the necessary charging infrastructure.
Long Charge Times Result in Operational Delays
As mentioned, potential delays resulting from long charging times can potentially impact fleet schedules and extend driver downtime, as it can take 30 minutes to two hours to achieve the typically desired 80% level of charge using a DC fast charger — significantly longer than it takes to refuel a diesel tractor — which can impact fleet schedules and must be considered during the planning process. If chargers are not available when needed, added delays must be factored into operational planning as well in order to ensure that delivery deadlines are met and can result in significant operational adjustments needing to be made.
Practical Decarbonization: Leveraging the Range eTrailer System for Scalable Electrification
In light of the various challenges associated with fleet electrification, Range Energy sought to provide a practical and scalable alternative and has delivered in the form of its hybrid eTrailer System. Founded by one of the earliest Tesla engineers and built with support from industry-leading heavy-duty EV experts, the company is well versed in the challenges associated with EV tractor adoption and introduced its unique hybrid solution as an achievable alternative to adopting EV tractors.
The Range Energy eTrailer System is a bolt-on addition for fleets that requires no major operational changes or disruptions. Furthermore, it is accessible to fleets of all sizes, as it does not require expensive charging infrastructure in order to utilize.
Immediate Deployment with Any Fleet
The bolt-on nature of the eTrailer System means that it can be used with existing fleet equipment without the need to purchase new tractors or trailers. The unit can easily be installed onto any existing commercial dry van or refrigerated trailer using basic tools and takes only a few hours to install. As a result, fleets are able to see immediate efficiency gains and cost savings with minimal downtime or impact to their operations.
The eTrailer System works by converting existing tractor-trailers into hybrid units using an EV powertrain that creates battery-powered propulsion, reducing strain on the tractor. It also features regenerative braking, applying power back to the battery for extended range, so companies see greater efficiency and fuel savings as well since less fuel is required to power the unit.
Charging During Existing Dwell Times
An added benefit of the eTrailer System is that it does not require dedicated charging stations and can be charged during existing dwell times due to its ability to use AC or DC chargers. While EV tractors require DC (Level 3) chargers, the eTrailer System is supported by AC systems as well, although DC chargers remain an option for fleets that have access to them. This translates into additional cost savings since fleets are not required to build out specialized charging systems and can use existing AC infrastructure to power them.
For states like California, where regulations (CARB) have pushed distribution facilities to install shore power plugs for refrigerated trailers, most facilities already have AC power available. Many also already have 480V 3-phase power supplied to their facilities, allowing reefer fleets to maximize existing infrastructure to both maintain proper trailer temperature and charge an eTrailer during existing dwell times for greater efficiency.
Cost Savings Without Infrastructure Investments
Because of their ability to use existing equipment and avoid costly infrastructure upgrades, fleets are able to see immediate cost savings and environmental benefits from the eTrailer System. Thanks to the eTrailer’s electric propulsion assistance that helps to power and reduce strain on the tractor, fleets are able to increase MPG by 50-70%. This leads to a 50%+ reduction in NOxemissions — savings that are achievable immediately once the eTrailer System is installed. Fleets also benefit from the added flexibility of being able to utilize existing AC power units to charge the trailers instead of being restricted to costly DC networks.
The Future of Fleet Electrification Doesn’t Rely on EVs
With a call to reduce Scope 3 carbon emissions and create greener supply chains to help meet the call for greater sustainability, fleets have looked to electrification as a challenging path forward. However, Range Energy’s hybrid eTrailer System provides a scalable alternative to complete electrification, allowing fleets to use the equipment they already have in place by providing a quick bolt-on solution to achieve immediate cost savings and efficiency gains.
With the ability to be applied to any commercial dry van or refrigerated trailer, the eTrailer System gives fleets the practical alternative they need to achieve greater efficiency and cost savings while meeting sustainability goals and requirements — all without the need to overhaul their existing operations or invest in expensive new equipment.
To learn more about Range Energy’s eTrailer System and how your fleet can achieve immediate cost savings and efficiency gains, complete our Pilot interest form to have a member of our team contact you to schedule a demo.