Making EV fleets work at scale: Why routes, utilisation and charging must evolve together – Abhinav Kalia, Co-Founder & CEO, ARC Electric

As India moves towards large-scale fleet electrification, integrating route planning, vehicle utilisation and charging infrastructure will be critical to achieving operational efficiency and sustainable EV fleet economics.

India’s electric mobility transition is entering a new phase. As electric vehicles move from pilot projects to commercial-scale deployment, the conversation is shifting from whether EVs can replace conventional vehicles to how fleets can make the transition without compromising utilisation, operational efficiency and profitability. For fleet operators, the challenge is no longer limited to selecting the right vehicle. It is about building an ecosystem where routes, vehicle utilisation and charging infrastructure work together.

From my experience working with fleet managers, one fact is clear: EV fleet success is not determined by vehicle technology alone. It depends on how effectively the vehicle, route and charging infrastructure are integrated. When these elements are planned independently, even a technologically advanced EV can deliver weaker-than-expected economics.

Start With the Route, Not the Vehicle

A fleet vehicle is an operating asset rather than a mere product. The value of a fleet vehicle is defined by how many kilometres it will be able to drive in a productive way every day.

The fixed employee transport route is very different from the on-demand mobility service in terms of operational flexibility, and the former can offer certain advantages in terms of charging due to predictable starting and ending points and long parking time.

This is the reason why route mapping needs to be done before vehicle procurement: companies need to analyze daily kilometres driven, traffic, number of trips and their frequencies, parking places and other related factors.

Utilisation Determines the Economics

Lower operating and maintenance costs are possible in electric vehicles, yet this becomes relevant for efficient usage of vehicles.

When talking about a high utilisation fleet, each additional kilometre that is productive can increase the efficiency of the asset. On the contrary, each extra charge and time when the vehicle is not in use has the same impact, but in reverse.

Thus, it is necessary to monitor not only the number of kilometres that were run, but also productive kilometres, idleness and charging time.

This means not just maximising utilisation but aligning it with charging opportunities.

Charging Must Follow Operations

This turns the charging infrastructure into a strategic choice and not just an infrastructure investment.

For a fleet that comes back to a base station every evening, the overnight charging can help in creating certainty. However, for continuous operation of the fleet, it would make sense to go for the opportunity to charge at the correct places. The model needs to depend on the route and duty cycle.

There are plans for developing the public charging stations in India. With the PM-E drive, there is a plan of investing ₹2,000 crores in the public EV charging infrastructure.

However, the dedicated fleet charging and public infrastructure need to work together. It would be impossible for the businesses to rely on the fact that the public charger will always be available whenever needed.

Scale Requires Local Planning

The problem gets even more complicated when organizations move past the big metropolitan areas, because each city is going to be different when it comes to traffic flow, parking facilities, power grid, and distance travelled.

In this way, a nationwide fleet system requires local operations systems. Rather than rolling out huge fleets of vehicles in multiple places at once, organizations can form smaller groups of operations, in which everything is better coordinated.

If these groups show reliable utilization and cost structure, the same concept can be applied to other places.

Data Can Connect the Three

Technology will enable quantification of this partnership. Fleet management solutions can monitor energy use, battery performance, efficiency in routing, charging patterns, and down times.

All this data can show areas where there is higher-than-expected energy use, where charging is skipped, or inefficient routes can be optimized. This data collected in one deployment can help in the future deployments.

In case of commercial fleets, even small changes in operations can matter a lot as they affect hundreds or thousands of vehicles.

The Real Challenge Is Building a System

India does not need its firms to electrify all the routes instantly. It requires that they identify the areas with the highest potential for both operational and economic benefits and expand on that.

Even the best EVs on bad route planning cannot yield great economic returns. An efficient charging network cannot help much if the route utilization rate is low. And route utilization without an efficient charging network can lead to operational risks.

This means that the future of electric fleets depends not so much on the speed at which the firm can deploy EVs, but on the ability of such firms to operate the fleet.

The real challenge is not to deploy EVs, but design the operations. With intelligent route planning, efficient vehicle utilization and appropriate charging infrastructure, electric mobility becomes not only more environmentally friendly, but also economically sustainable. This is what India needs to transition to electric mobility on a large scale.