Optimising HGV charging infrastructure & reducing network charges

The transition to electric HGVs is rapidly gaining momentum. Driven by CO₂ targets (ESG), toll exemptions and revenues from the GHG quota, the first electric fleets are rolling into depots. Yet scaling often fails due to the local grid connection: uncontrolled charging leads to massive peak loads and exploding costs. We show you how to optimise your HGV charging infrastructure and save significant costs through smart energy management.

What does it mean to optimise HGV charging infrastructure?

Optimising HGV charging infrastructure involves the intelligent control of charging processes. The goal is to synchronise the energy demand of the electric fleet with the site’s load profile to avoid grid congestion and minimise network charges through peak shaving.

The challenge: the “15-minute trap” at the depot

To calculate network charges for logistics sites, Germany uses a special system: the so-called capacity-based tariff. This means you pay not only for the electricity you actually consume (energy charge), but also for the “reservation” of maximum capacity in the electricity grid (capacity charge).

The tricky part: the highest peak load measured within a single 15-minute interval during the entire year often determines the price for the whole year.

A simple example: imagine your depot operates steadily throughout the year. But on one evening in January, all electric HGVs plug into the fast chargers at the same time. That single 15-minute peak can dramatically increase your electricity bill for the next 12 months.

When a modern logistics site transitions to e-mobility, megawatt-scale loads quickly accumulate. Without intelligent control of charging processes and energy flows, the risks include:

• Enormous network charges: Uncontrolled charging at the wrong time can double annual fixed costs.
• Costly grid expansion: If demand exceeds the existing grid connection capacity, grid operators often require six-figure investments for new transformers and cabling.

Strategies to optimise HGV charging infrastructure

To optimise HGV charging infrastructure, installing hardware alone is not enough. The intelligence lies in the software.

1. Dynamic Load Management (DLM)

Instead of assigning each charging point a fixed, rigid capacity, an intelligent load management system dynamically distributes available energy according to demand. The system operates on two levels:

First, charging power for HGVs is automatically aligned with major on-site consumers such as energy-intensive refrigeration systems or sorting equipment. If these assets push the grid connection towards its limit, the charging power of the electric HGVs is temporarily reduced.

Even more critical for operating costs, however, is time-based coordination: the system intelligently distributes charging processes across the entire dwell time (e.g. overnight). Instead of charging all vehicles at maximum capacity as soon as they plug in, energy delivery is spread out so that all batteries are fully charged by morning, without ever creating an expensive grid peak.

2. Peak shaving through battery storage

A local battery storage system acts as a highly efficient buffer for your site. Its primary purpose is peak shaving:

• Reducing network charges: You prevent a short peak during HGV charging from increasing your annual capacity charge.
• Avoiding grid expansion: The battery provides the necessary “extra power” when the physical grid connection capacity is no longer sufficient for the number of vehicles.

In most cases, this combination of storage and smart control is significantly more cost-effective and faster to implement than an expensive physical grid upgrade by the distribution system operator.

3. Sector coupling: PV systems and depot charging

The large roof areas of logistics centres are ideal for photovoltaic systems. An smart energy management system (EMS) ensures that electric HGVs are primarily charged when the sun is shining. This not only improves the CO₂ footprint but also significantly reduces electricity drawn from the grid.

Frequently asked questions about optimising HGV charging infrastructure

1. How can I optimise my HGV fleet’s charging infrastructure without disrupting operations? The key is prioritisation. Not every HGV needs to charge immediately at maximum capacity. By integrating telematics data, the system knows when each vehicle is scheduled to depart and distributes energy over the available dwell time accordingly.
2. How does the cost of grid expansion compare to intelligent load management? A grid upgrade can cost several hundred thousand euros depending on the region and distance to the substation and may take months to implement. Intelligent load management solutions from providers such as encentive are often operational in a fraction of the time and typically refinance themselves quickly through reduced network charges alone.
3. Do dynamic electricity tariffs play a role? Absolutely. To minimise operating costs for electric HGVs, the combination of smart control and the right procurement strategy is crucial. The prerequisite is a dynamic electricity tariff or partially flexible procurement via the spot market (exchange electricity price). Unlike traditional fixed-price contracts, these models allow you to benefit from price fluctuations. An intelligent energy management system (EMS) fully automates this process: it schedules charging cycles primarily during periods of high renewable generation (wind and solar). During these phases, wholesale electricity prices are particularly low, sometimes even zero. Anyone looking to optimise HGV charging infrastructure should therefore use fleet flexibility to purchase electricity when supply is high and prices are low.

The situation in Germany

Particularly in German commercial and industrial areas, grid capacity is often limited. Regional distribution system operators frequently demand six-figure construction cost contributions for new transformers when capacity limits are exceeded. By optimising your charging infrastructure, you position yourself as a grid-supportive participant. This not only accelerates approval processes for new charging points but also protects you from unpredictable investment costs.

Conclusion: Act instead of react

The transition to electric HGVs is far more than simply replacing vehicles. It is an opportunity to fundamentally future-proof and cost-optimise your entire site’s energy supply. Those who invest today in optimising their HGV charging infrastructure make their operations independent of rigid grid constraints and leverage energy market volatility to their advantage. In this way, you avoid tomorrow’s cost traps and secure a genuine competitive edge in a green logistics landscape.

Would you like to find out how much potential lies within your site? Book a consultation with us.