PowerFlex Provides Intelligent Fleet EV Charging for DHL Last-Mile Deliveries Throughout the U.S.

DHL is a global logistics leader with 600,000 employees in more than 200 countries. The company has set a goal to achieve net-zero emissions by 2050, and DHL’s Express division aims to electrify 66% of its last-mile delivery vehicles by 2030. As part of its commitment to a sustainable future, DHL has invested in multiple green initiatives, including the adoption of electric vehicles for last-mile deliveries.

The Challenge

Deploying Cost Effective Fleet EV Charging at Scale

Reliability is critical for an international logistics giant like DHL—fulfilling customer shipments on time each and every day is nonnegotiable. Electrifying DHL Express’ last-mile fleet requires an EV charging solution that meets the demands of its busy distribution centers: with 40–60 vehicles per site, delivery routes of up to 300 miles or more, and a schedule that demands vehicles must be ready to depart by as early as 6 a.m.

PowerFlex’s Solution

Intelligent, Scalable Fleet EV Charging Optimized by Adaptive Load Management®

INSTALLATION TYPE

Fleet EV Charging System

INSTALLATION SIZE

730+ Level 2 Chargers across 16 sites

LOCATIONS

10 states including CA, FL, IL, NY, OR

INCENTIVES

CALeVIP • Fast Charging Infrastructure (FCI) • Low Carbon Fuel Standard (LCFS) • Self-Generation Incentive Program (SGIP) • Demand Side Grid Support Program • Communities in Charge

PowerFlex provided DHL with a turnkey, large-scale EV charging network, installing more than 730 Level 2 chargers at 16 sites across the U.S. The chargers are managed by PowerFlex’s intelligent energy management platform, PowerFlex X™, which leverages patented Adaptive Load Management® (ALM) algorithms to balance power usage across the charging network. This approach reduces electrical capacity requirements and long-term operational energy costs, allowing DHL to install twice as many chargers compared to unmanaged charging — all within the same power limit and existing electrical infrastructure.

With PowerFlex X, fleet personnel can monitor charging operations at specific locations and view aggregated metrics across DHL’s entire portfolio of electrified sites. The system also integrates with DHL’s telematics, providing real-time data on vehicle state of charge, schedule information, estimated range, vehicle location, and route information.

“We selected PowerFlex to complete our EV charging stations because of their deep industry experience that helped us find a creative solution to meet our EV fleet charging needs. We look forward to scaling up our EV fleet and ensuring reliable, eco-friendly deliveries to our customers.”

Laurice Bancroft

SVP of Network Operations, DHL Express U.S.

Unmatched Charger and Vehicle Visibility With PowerFlex X Fleet+

DHL also has access to PowerFlex X Fleet+™— an online dashboard designed for fleet depot managers. It displays the status of all fleet charging stations in a single view and is sortable by charging status, station type, and time remaining in the charge session. Integrated telematics display critical vehicle information, including state of charge, schedule, estimated range, vehicle location within the depot or out in the field, and route information.

Building a National Fleet Charging Network for DHL

Recently, PowerFlex deployed 96 EV charging stations as part of a large-scale charging solution at DHL’s new state-of-the-art facility in McCook, Illinois. Serving the busy Chicago metro area, the facility is equipped with cutting-edge automation that will speed up fulfillment and serve as a model for other DHL locations. PowerFlex’s onsite charging system gets DHL even closer to achieving its ambitious fleet electrification goal.