Summit Industrial Supply ran 65 Class 6 delivery trucks and 55 company cars across a six-state territory. Combined fuel spend: $1.78M per year. The CFO had flagged it twice in board meetings. The fleet director had explored EVs and shelved it three times range anxiety for the trucks, home charging complexity for the car fleet, and no single platform that could manage both. The fourth time, they brought in FleetRabbit. Twenty-four months later, all 120 vehicles are electric, and the company saves $1.2M every year. This is the full story. Book a demo to see how FleetRabbit handles mixed EV fleet transitions.
Why This Transition Had Been Shelved Three Times
Most EV fleet case studies start with the results. This one starts with why it almost didn't happen — because the obstacles Summit faced are the same ones sitting on most fleet directors' desks right now.
Summit's Class 6 trucks ran routes averaging 95–130 miles daily across industrial corridors. Current electric Class 6 models have real-world ranges of 150–180 miles in optimal conditions — shrinking to 120–140 miles in cold weather under full payload. That margin felt too thin to commit capital on. Fleet director Marcus Webb ran a back-of-envelope calculation, got uncomfortable, and shelved the project. What he was missing: FleetRabbit's route analysis showed 57 of the 65 truck routes fit comfortably within EV range even in winter. The remaining 8 needed a single DCFC midpoint stop — mapped to locations that overlapped with drivers' existing rest breaks.
55 company cars driven by salespeople and field staff meant 55 different home addresses, 55 different electricity providers, 55 different billing cycles, and zero existing process for tracking which charging was work vs. personal. HR had estimated the monthly reimbursement processing at 45 minutes per driver. Multiplied across 55 drivers, that was 41 hours of monthly admin time that didn't exist in anyone's job description. FleetRabbit's home charging reimbursement module automated the entire calculation — smart charger integration tracked every session, split work vs. personal automatically, and sent finance a one-click monthly report. Zero manual processing.
Every EV fleet management tool Marcus evaluated handled either trucks or cars well — not both. Truck-focused platforms couldn't manage home charging reimbursement. Car fleet platforms had no DCFC load management or route range analysis for commercial vehicles. Running two platforms meant two dashboards, two reports, and a manual CFO summary every month that reconciled neither. FleetRabbit managed both fleet types natively — trucks with depot DCFC scheduling and range analysis, cars with home charging reimbursement and office L2 scheduling — under one unified dashboard and one monthly report. See the unified dashboard in a demo →
The Fleet: Two Asset Types, Two Completely Different Transitions
We'd looked at this three times and walked away three times. The math always worked — it was the execution risk that stopped us. FleetRabbit showed us exactly which routes fit, exactly what the infrastructure would cost, and exactly what we'd save. There was nothing left to be uncertain about.
How the 24-Month Transition Actually Unfolded
Summit chose a sequential strategy — cars first, then trucks — to build internal EV operations knowledge on the lower-risk asset before tackling the higher-complexity commercial vehicles.
Office L2 chargers installed. Home charger stipend program launched. All 55 car fleet drivers onboarded to FleetRabbit's home charging reimbursement. Route analysis cleared all 55 cars for immediate EV transition.
All 55 company cars transitioned to electric. Home charging reimbursement running automatically from day one. Sales team concerns resolved within 30 days. 97% driver satisfaction at 90-day survey. FleetRabbit team begins truck route analysis in parallel.
8 × 150kW DCFC installed at depot. Smart load management activated — demand peak capped at 600kW. First 30 Class 6 trucks transitioned on the easiest routes. Truck drivers trained. Cold weather protocol built and tested through first winter season.
Remaining 35 trucks transitioned. 8 long-route trucks running with planned DCFC midpoint stops. Full mixed-fleet dashboard live. Last diesel vehicle retired. Zero-emission fleet status achieved and reported in ESG disclosure. $1.2M annual savings confirmed by finance.
12-Month Results After Full Transition — Verified by Finance
Here is the complete financial and operational breakdown across both fleet types. Sign up free to start tracking your own EV transition metrics.
What Drivers Actually Said
The truck drivers and car drivers had entirely different concerns going in — and entirely different experiences coming out.
Before & After — The Full Operations Comparison
Frequently Asked Questions
Should we transition cars or trucks first?+
For most mixed fleets, cars first is the lower-risk sequencing. Car electrification has wider range margins, simpler charging infrastructure (home L2 vs. commercial DCFC), faster ROI, and easier driver adoption — building internal organizational knowledge before tackling the more complex truck transition. Summit followed this sequence and credited it with making the truck transition significantly smoother. That said, FleetRabbit's suitability analysis scores both fleet types independently and recommends sequencing based on your specific routes, infrastructure options, and risk tolerance — not a generic formula.
How do you handle Class 6 truck routes over 120 miles?+
FleetRabbit's route analysis identified Summit's 8 long-route trucks before any vehicles were ordered. For each, we mapped the nearest public 150kW+ DCFC location that fell within the first half of the route and overlapped with the driver's existing rest break requirement. The DCFC stop adds 35–45 minutes — time the driver would have stopped anyway under HOS rules. FleetRabbit's dispatch interface builds the charging stop into the route schedule automatically on applicable days. Over 24 months, zero of these 8 routes experienced a range-related disruption. Run your truck routes through FleetRabbit's analysis →
How does home charging reimbursement work for car fleet drivers?+
FleetRabbit integrates with smart home chargers (ChargePoint Home, JuiceBox, Enel X, and others) to automatically track each charging session's energy usage and cost. The system splits business vs. personal charging based on the driver's scheduled work days and departure times — reimbursing only work-attributable energy. Finance receives a monthly report with per-driver breakdowns requiring zero manual input. Summit eliminated 41 hours of monthly processing across 55 drivers on day one of activation.
How do you prevent huge electricity bills from multiple fast chargers?+
FleetRabbit's smart load management staggers charging sessions based on each truck's scheduled departure, current state of charge, and priority level. Summit's 8 × 150kW DCFC chargers could theoretically draw 1.2MW simultaneously — enough to trigger severe utility demand charges. FleetRabbit capped peak demand at 600kW by staggering session starts. This saved $41,000 annually in avoided demand charges — a cost that catches most fleet managers off guard after DCFC installation without load management.
What if we have fewer than 120 vehicles?+
FleetRabbit supports mixed EV fleet transitions from 5 vehicles upward. Smaller mixed fleets often see higher percentage ROI because operational inefficiency tends to be more pronounced in smaller operations. The same capabilities — dual fleet type management, home charging reimbursement, truck route analysis, DCFC load management, unified reporting — are available regardless of fleet size. Book a demo for your fleet size →
Trucks. Cars. One Platform. One Transition That Actually Works.
FleetRabbit manages the full complexity of mixed fleet electrification — separate charging strategies, separate driver populations, one unified dashboard — so you get the $1.2M savings without building it yourself.
Free for up to 3 vehicles · Mixed fleet assessment in 48 hours · US, AU, UK, CA fleets supported
