Case Study: Electric Van Fleet Extends Range by 14% with Speed Limiter Programme
Case Study: Electric Van Fleet Extends Range by 14% with Speed Limiter Programme
Illustrative case study representing typical results achievable by electric vehicle fleet operators using AutoKontrol speed limiter technology.
Overview
| Detail | Information |
|---|---|
| Sector | Facilities management and building services |
| Fleet size | 60 electric vans |
| Vehicle types | Medium electric vans (e-Transit class, 68 kWh battery) |
| Operating area | Birmingham, Coventry, and West Midlands |
| Deployment period | 4 months |
| Key result | 14% real-world range extension |
| Annual energy cost saving | £34,000 |
| Range anxiety incidents eliminated | 100% |
| ROI achieved | Month 5 |
A national facilities management company had committed to electrifying its van fleet across the West Midlands region as part of a corporate net-zero target. The first phase — 60 electric vans replacing diesel equivalents — was deployed on time and under budget. The problems started within six weeks.
Real-world range was consistently falling 20-30% below the manufacturer’s stated figures. Vehicles were running out of charge mid-route, requiring emergency recovery. Drivers were “range anxious” and requesting diesel vehicles. And the energy cost savings that had underpinned the electrification business case were 15% below projection.
The root cause was straightforward: driving behaviour optimised for diesel vehicles — specifically high dual carriageway speeds and aggressive acceleration — was catastrophically inefficient for electric vehicles. The company engaged AutoKontrol to deploy TrackSpeed with speed and energy management profiles specifically designed for EV operations. The result was a 14% real-world range extension, the elimination of mid-route charge failures, and £34,000 in annual energy savings.
The Challenge
The Range Gap: Expectation vs Reality
The electric vans had a manufacturer-stated range of 195 miles (WLTP). In the company’s operating conditions — a mix of urban multi-stop routes and dual carriageway transit between areas — real-world range was averaging 138 miles. On cold winter days with heating running, this dropped to 118 miles.
Several routes in the network required 145-160 miles of daily driving. These routes had been planned on the assumption of 165-mile operational range (a conservative 85% of WLTP). At 138 miles actual range, the routes were simply not feasible without mid-day charging — and the charging infrastructure to support that did not exist.
Eight Recovery Incidents in Six Weeks
In the first six weeks of operation, eight vehicles ran out of charge during their routes and required flatbed recovery to the nearest rapid charger or back to depot. Each recovery cost an average of £280 and resulted in incomplete delivery routes, requiring a second vehicle to complete the remaining stops.
The total direct cost of the eight incidents was £2,240 in recovery charges plus an estimated £4,800 in lost productivity. But the indirect cost was worse: driver confidence collapsed. Of the 60 drivers assigned to electric vans, 23 formally requested transfers back to diesel vehicles within the first two months.
Energy Cost Underperformance
The electrification business case had projected energy costs of £0.04 per mile (based on overnight depot charging at a negotiated commercial tariff). Actual energy consumption was averaging £0.047 per mile — 18% above projection. Across 60 vehicles averaging 35,000 miles per year, this represented a £14,700 annual shortfall against the business case.
The culprit was energy consumption at higher speeds. Electric motors are most efficient at moderate, steady speeds. At 65-70 mph on dual carriageways, energy consumption per mile increases dramatically — by 35-50% compared to 50 mph. Diesel vehicles also consume more fuel at higher speeds, but the penalty is proportionally much smaller. Drivers trained on diesel habits were applying diesel driving patterns to electric vehicles, with predictable results.
The Solution
TrackSpeed: EV-Optimised Speed Profiles
AutoKontrol deployed TrackSpeed across all 60 electric vans with speed profiles specifically designed to maximise EV range and energy efficiency.
Dual carriageway limit: 60 mph. While the legal limit for vans on dual carriageways is 60 mph (70 mph on motorways where applicable), many drivers habitually operated at 65-70 mph on dual carriageways. TrackSpeed was configured to enforce a hard 60 mph limit on dual carriageways and a 65 mph advisory on motorways. This single change — keeping vehicles at or below 60 mph rather than 65-70 mph — was the primary driver of the range improvement.
Urban zone profiles (GeoKontrol): The West Midlands operating area included 44 designated 20 mph zones. GeoKontrol was configured to enforce these automatically. In EV terms, the benefit was dual: reduced speed in urban zones improved range, and the gentler acceleration required after each stop reduced the sharp energy draws that depleted the battery disproportionately.
Eco-driving alerts: TrackSpeed was configured to provide real-time in-cab feedback on energy-efficient driving behaviours: smooth acceleration, consistent speed maintenance, and anticipatory braking (maximising regenerative braking recovery). These alerts were advisory rather than enforced, but they were informed by the speed data and contributed to the overall efficiency improvement.
Range Confidence Dashboard
AutoKontrol worked with the company’s fleet management team to create a real-time range confidence dashboard. Each vehicle displayed its current battery state of charge, estimated remaining range based on actual (not theoretical) consumption patterns, and a green/amber/red status indicating whether the remaining route was achievable on current charge.
This dashboard addressed range anxiety directly. Drivers could see, in real time, that their vehicle had sufficient range to complete the route. The amber warning triggered at 15% remaining range, providing sufficient buffer for the driver to reach a charger or adjust the route.
Driver EV Transition Training
AutoKontrol provided a half-day EV-specific driver briefing programme, covering:
- Why speed affects EV range disproportionately compared to diesel
- How regenerative braking works and how to maximise energy recovery
- How to read the range confidence dashboard and respond to warnings
- Why the speed profiles were set where they were — connecting the technology to the driver’s daily experience
The briefing was practical and empathetic. Many drivers were anxious about EVs because of the early recovery incidents. The combination of speed management technology and driver education rebuilt confidence.
Results
Range and Energy Performance (12 Months Post Deployment)
| Metric | Before | After | Change |
|---|---|---|---|
| Average real-world range | 138 miles | 157 miles | +14% |
| Winter range (worst month) | 118 miles | 134 miles | +14% |
| Energy consumption per mile | £0.047 | £0.038 | -19% |
| Mid-route charge failures | 8 (in 6 weeks) | 0 (in 12 months) | -100% |
| Drivers requesting diesel transfer | 23 | 2 | -91% |
Financial Impact
| Category | Annual Amount |
|---|---|
| Energy cost reduction (60 vehicles) | £34,000 |
| Eliminated recovery costs | £8,400 (annualised from initial rate) |
| Eliminated lost productivity from charge failures | £14,400 (annualised) |
| Tyre cost reduction | £6,200 |
| Total annual benefit | £63,000 |
Deployment Costs
| Item | Amount |
|---|---|
| TrackSpeed + GeoKontrol hardware and installation (60 vehicles) | £42,000 |
| Annual subscription | £18,000 |
| Driver training programme | £4,800 |
| Year one total cost | £64,800 |
| Payback period | 5 months |
Corporate Sustainability Impact
The range extension had a secondary benefit that resonated at board level. By maintaining EV operational viability across more routes, the company avoided reverting three routes to diesel vehicles — a reversion that would have generated approximately 42 tonnes of CO2 per year and undermined the credibility of the corporate net-zero commitment.
The company’s sustainability report cited the AutoKontrol deployment as “instrumental in ensuring the EV transition delivers its environmental promise in practice, not just in policy.”
What the Fleet Manager Said
“We nearly gave up on EVs after the first month. Vehicles running out of charge, drivers refusing to drive them, the business case falling apart. TrackSpeed gave us back 19 miles of real-world range by doing something remarkably simple: keeping the vans at 60 mph instead of 70. That was the difference between routes that worked and routes that didn’t. The technology saved our electrification programme.”
Regional Fleet Manager, facilities management company
Key Takeaways
- Electric vehicles are disproportionately sensitive to speed — the range penalty for 70 mph vs 60 mph is 35-50%, far greater than the equivalent diesel penalty
- Speed management is not just a safety tool for EV fleets — it is an operational viability tool that directly determines whether routes are achievable
- Range anxiety is a real driver welfare issue that technology can address — the range confidence dashboard was as important as the speed profiles
- The energy cost saving from speed management compounds the environmental benefit of electrification
- Driver training specific to EV characteristics is essential — diesel habits applied to EVs produce poor outcomes
- Corporate net-zero commitments depend on EV deployments succeeding operationally — speed management protects that strategic investment
Could Your Fleet Achieve Similar Results?
AutoKontrol is increasingly working with operators transitioning to electric vehicles. Our TrackSpeed solution is compatible with all major electric van platforms, and our EV-specific speed profiles are designed to maximise range and energy efficiency while maintaining operational productivity.
Whether you are planning an EV transition, mid-deployment and experiencing range challenges, or looking to optimise an existing electric fleet, our team can design a programme that makes your electrification investment work in practice.
Learn more about speed limiters for electric and hybrid vehicles, explore speed limiters and last-mile electric delivery, or read about reducing fleet carbon emissions with speed limiters.
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