At the 2025 Australasian Fleet Education & Leadership Summit, Ralton Benn, Project Manager at Cape Dunstans, shared an inspiring case study on the rollout of electric vehicle (EV) charging infrastructure for heavy trucks operated by Centurion Transport. More than just a technical achievement, the project revealed the critical importance of early stakeholder engagement, cross-functional collaboration, and a pragmatic approach to complex infrastructure deployment in brownfield sites.
The Vision Behind the Project
Backed by ARENA and the Driving the Nation Program, this ambitious pilot program seeks to deploy 30 Mercedes-Benz eActros electric heavy-duty trucks into Centurion’s Perth logistics operation. It features two off-grid renewable energy charging hubs with over 4 megawatts of solar generation and 14 megawatt-hours of battery storage—completely independent from the grid.
The aim? To explore the viability of battery-electric trucks for first-mile and last-mile logistics, while proving the business case through lower operational costs and reduced emissions. As Benn noted, “Without a successful pilot, you’re not going to move beyond it.”
People First: The Role of Stakeholders
While the project features state-of-the-art technology, it was people who made it successful. Ralton Benn emphasised that “people are the influencers, the optimisers, and the advancers of the technologies,” and he credited strong stakeholder management as the backbone of the project’s success.
Cape Dunstans developed a layered communication strategy. Early discussions focused on executives, ensuring alignment on project governance and objectives. As implementation progressed, engagement shifted to senior operational managers, and eventually to team leaders, drivers, trainers, and health and safety staff. This deep integration of end users into the design and construction process led to practical deliverables tailored to real-world needs.
Overcoming Implementation Challenges
Installing off-grid charging infrastructure in a 24/7 logistics hub presented unique hurdles. The Perth site was already operating at capacity, and connecting to the grid would have taken two years and incurred unsustainable costs. The team responded by designing two self-contained solar and battery systems that sit within grid-connected lots but operate independently.
Construction in a live logistics environment required creative solutions. With minimal tolerance for downtime, Cape Dunstans employed horizontal drilling to lay nearly three kilometres of cabling under the site—minimising disruption while maintaining site operations.
The team also confronted regulatory ambiguity. These off-grid systems were novel, and existing electrical codes didn’t address their specific requirements. Collaborative engagement with state authorities resulted in a compliance solution, including the unique approach of interlinking the EV charging system to the site’s emergency power shutdown.
Collaborative Design and Operational Readiness
Co-design was embedded throughout the process, ensuring that the system would be workable and effective in the real world. Cape Dunstans convened end users, designers, and installers at key milestones, and even during construction. As Benn described, “We brought the end user onto the ground where we’re actually constructing as well.”
Centurion’s commitment to operational readiness was equally critical. They developed procedures, HR frameworks, emergency response plans, and driver training modules so that the first 20 vehicles could begin work immediately when the infrastructure went live in February. The final 10 trucks are expected to join the fleet in June or July.
Integrated Monitoring and Knowledge Sharing
A sophisticated energy management portal now monitors every element of the system—from solar generation and battery charge to vehicle charging events and consumption patterns. This platform will eventually integrate real-time vehicle telematics to help Centurion optimise operations and prove the business case against diesel alternatives.
The project also includes a knowledge-sharing component through ARENA, with Cape Dunstans capturing learnings via maintenance logs, driver surveys, and stakeholder feedback. “The goal,” Benn said, “is to understand what’s required for these fleets to achieve price parity with diesel.”
Lessons for the Broader Industry
Ralton Benn closed his presentation with a series of insights that will resonate with fleet managers and energy transition leaders:
- Net zero is a journey, not a one-size-fits-all event. The Centurion project worked because it fit the company’s ESG goals, operational profile, and appetite for innovation.
- Robust relationships with OEMs are crucial. Collaboration with Daimler (Mercedes-Benz) gave Cape Dunstans valuable insights into performance, costs, and limitations.
- Charging infrastructure needs a long-term view. The solar panels used in this project have a 30-year warranty—far exceeding the life of the initial truck fleet.
- Right truck, right task. Consistent routes, like port-to-depot work, are ideal candidates for electrification. Range assumptions must be realistic, and asset swaps should be anticipated.
- Infrastructure costs must be understood separately. Some capital investments will outlast a vehicle’s useful life and should be amortised accordingly.
Final Thoughts
This project demonstrates what’s possible when technology, people, and purpose align. For fleet managers contemplating similar transitions, the Centurion case study offers a valuable blueprint. As Benn reflected, “Choosing the right EV for the right use, and having confidence in what the OEM tells you, will help you plan better and transition faster.”
With real vehicles in operation and lessons already being applied to future projects, Centurion and Cape Dunstans are showing how complex, large-scale charging infrastructure for heavy vehicles can become a reality—with the right team, the right vision, and the right plan.
