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The transition from diesel to EV in yard operations is more than a simple swap of vehicles — it’s an operational transformation. Too many organizations dive straight into equipment procurement and charging infrastructure without building the data foundation needed for success. The result? Cost overruns, bottlenecks, and underperforming rollouts.
Today, electrification is moving fast: fleets operating electric yard trucks are achieving uptimes of over 97% rivaling diesel performance, and many are scaling pilots to fleets of 100+ trucks per site. These results prove that EV yard operations aren’t just viable; they’re efficient and scalable when planned with data-driven precision.
Here’s how to approach the transition with the right foundation.
Underestimating Power and
Infrastructure Needs
Start by benchmarking your current yard performance. Gather data on fuel consumption, idle time, throughput, and energy use. Establish an emissions baseline and set specific, measurable ESG goals.
This groundwork lets you model how EVs will perform in your environment — from load requirements to charge cycles — and predict the operational and environmental impact before making major investments.
At NSSL, we combine operational expertise with real-time analytics to
help clients align emissions goals with operational realities.
Design Smarter Charger Layouts
and Power Infrastructure
The physical design of your yard has a direct impact on EV efficiency. Charger locations should minimize cable runs, reduce congestion, and balance power distribution. Engage with utilities early to confirm power capacity and understand upgrade timelines. Infrastructure delays can be the single biggest rollout hurdle.
NSSL’s EV rollout process integrates charger layout planning with load balancing to ensure every yard has the flexibility and redundancy needed to scale.
Overlooking Software and Data Visibility
Yard operations peak during shift changes and loading surges. Charging schedules that overlap with those windows can strain both the power grid and your throughput.
By using data-driven scheduling, you can align charging with idle time and lower-demand periods, maintaining productivity and uptime. During pilot phases, NSSL uses Shuntware® to simulate multiple load scenarios ensuring peak efficiency before full deployment.
Pilot First, Scale with Confidence
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.
Uptime
percentage
Idle time
reduction
Energy per
move
Cost per move
vs. diesel
CO₂
reduction
NSSL’s pilot-to-scale methodology validates every assumption before expansion — helping organizations move from concept to network rollout with measurable confidence.
The Bottom Line
Transitioning from diesel to EV isn’t about replacement — it’s about transformation. With the right data, modeling, and methodology, you can build a yard that’s cleaner, smarter, and ready for the future.
See where your site stands and how to prepare for electrification success.
Download the EV Readiness Checklist