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Hidden Pitfalls of EV Rollouts
(and How to Avoid Them)

Electric yard fleets offer huge advantages in cost, efficiency, and emissions but not every rollout delivers those benefits. Many fail for reasons that have little to do with the trucks themselves.

In a 2025 fleet study, 33% of logistics professionals cited infrastructure complexity as their top electrification challenge. The reality is that success depends on the planning that happens long before the first charger is installed.

Here are the five hidden pitfalls to watch out for — and how to avoid them. 

Lowering Fuel Ccosts
1

Underestimating Power and
Infrastructure Needs 

Even the best rollout plan can falter if your yard’s electrical infrastructure can’t handle the load. Many sites discover too late that transformers, panels, or feeder cables are undersized. 

Avoid it:

Conduct a full-site power assessment and engage utilities early. Build redundancy and buffer capacity for growth. NSSL’s EV rollout process includes complete site modeling to ensure chargers, distribution, and load management are future-ready. 

2

Ignoring Peak Window Conflicts 

Charging too many trucks during busy operational windows can create major slowdowns. Without coordinated scheduling, you risk bottlenecks and grid strain.

Avoid it:

Conduct a full-site power assessment and engage utilities early. Build redundancy and buffer capacity for growth. NSSL’s EV rollout process includes complete site modeling to ensure chargers, distribution, and load management are future-ready. 

3

Skipping Change Management
and Training 

People are the linchpin of every successful rollout. Operators and maintenance staff need to adapt to new routines, safety procedures, and data tools.

Skipping Change Management and Training 

Avoid it:

Build a structured training plan early. Include operational simulations and clear SOPs for charging and dispatch. NSSL provides on-site training to help crews adapt seamlessly to new technology. 

4

Overlooking Software and Data Visibility 

Hardware is just one piece of the puzzle. Without visibility into energy use, charger performance, and emissions, decision-making becomes reactive and inefficient. 

Avoid it:

Implement yard management software with real-time dashboards and emissions tracking. Shuntware® provides actionable insights into energy use, charge status, and performance — making electrification measurable and manageable. 

Scaling Too Quickly Without Lessons Learned
5

Scaling Too Quickly Without
Lessons Learned

Even successful pilots can fail at scale if conditions vary by site — from layout to weather to power availability. 

Avoid it:

Use a measured rollout. Apply pilot learnings to a standardized playbook but stay flexible to local conditions. NSSL’s pilot-to-scale approach ensures each yard meets performance benchmarks before expanding network-wide.

The Takeaway 

EV adoption is more than a hardware upgrade — it’s an operational evolution. The right strategy, software, and support make the difference between challenges and long-term success. 

Start building your roadmap to reliable, scalable electrification in your yard. 

Book a Free EV Consultation