Electric machines stack up for Reliance Transport

Reliance Transport is proving that electric off-road vehicles can not only do the job of their diesel counterparts but surpass them in many ways.

The last-mile transport company purchased an electric reach stacker in 2023, the 20th addition to its fleet of electric machines.

Reach stackers are used primarily in ports, warehouses, storage yards and distribution centres. They are designed to lift, move and stack heavy loads, such as shipping containers.

Electric reach stackers offer several advantages over diesel-fuelled stackers, providing significant operational savings and improved driver experience.

This case study details how the new electric reach stacker and other electric machines have contributed to emissions savings, operational efficiency and cost-saving benefits for Reliance Transport.

A new standard in performance

Reliance Transport relies on the electric reach stacker for a majority of its Wiri depot’s container movements. During peak times, the stacker undertakes around 100 container movements per day, making it the most heavily used machine on site.

The company uses its on-site 40kW fast charger to fully charge the vehicle overnight. The stacker regularly gets through full 8-hour shifts, consuming around 33kWh of electricity per hour. At times when it’s needed for a longer period, it’s topped up during staff breaks during the day, usually using electricity from the depot’s solar microgrid.

Significant savings in energy costs

Due to the cheaper cost of electricity compared to diesel, Reliance Transport has achieved an 80% reduction in energy costs from the reach stacker.

The vehicle is also proving to be around 65% cheaper to maintain than their previous diesel equivalent. This is due to the electric stacker having fewer moving parts, and not needing engine oil or gearbox maintenance.

"It's important for Reliance to look after its customers, its staff and its shareholders. Cost savings means we can all share in the benefits of it." 

Mark Darrah, General Manager, Reliance Transport 

On top of cost savings, the electric reach stacker’s carbon emissions are 90% lower than the previous diesel machine.  

A winner with machine operators

Reliance Transport’s drivers have found the electric reach stacker to be quieter, more responsive, and easier to drive. It’s smoother, with significantly less vibrations and effort required to pilot the machine. 

This has meant that they have been able to operate the machine for longer periods without needing a break. Drivers are finishing shifts less tired, leading to improvements in staff satisfaction. 

“The lack of noise pollution is incredible with this machine, it’s zero. My guys feel pretty good about driving it.”

Adrian Ediss, Freight Manager and Reach Stacker Operator, Reliance Transport 

Lessons in charging

Understanding electricity supply to sites is an important first step for any company looking to electrify its fleet.  
One challenge Reliance Transport encountered was that the grid supply to their depot limited the charging capacity it could install. 

By analysing the reach stacker’s operational patterns and energy consumption, the company was able to come up with a workable solution with a slower charger.

The stacker is mostly operated during day shifts, which means there is plenty of time to charge the machine overnight. But there are times when the reach stacker must do longer shifts, so it was important to install a DC charger that could give a quick top up when needed.

Reliance Transport opted to install a 40kW charger, which is sufficient to maintain a standard operating procedure, with minimal loss in productivity. 

The company is aiming to increase its charging capacity, and is trialling rooftop solar to supply more energy onsite.  

Following an emissions reduction plan

The electric reach stacker is part of Reliance Transport’s emissions reduction pathway ‘Project Switch’.

Project Switch is an eight-stage plan to guide Reliance Transport on its journey to achieve carbon neutrality and operational efficiency for the company over several years.

Having a good understanding of its asset replacement strategy and emissions sources was essential. Diesel is the company’s largest source of emissions, so its focus was on replacing high diesel-use machines that are near their end of life with electric options.

Scaling was another important factor. The company identified the need to start small, first trialling electric light commercial and passenger vehicles. It has since invested in an electric forklift, two large electric Scania 25P trucks, and most recently an electric hoist and the reach stacker.

At each step of this journey, Reliance Transport learned more about electric machines, including their advantages and limitations and how best to incorporate them into its processes. This deliberate and gradual process limited risk and interruptions to operations.

Looking to the future

For Reliance Transport, the electric reach stacker is just the latest step in a long journey toward fully electrifying its fleet. 

In the near term, the company is planning to purchase more electric trucks, including the latest heavy transport truck from Scania. The long-term plan is to construct a purpose-built depot with sufficient solar capacity to support super-fast megawatt charging, a new charging standard that will be coming to New Zealand in the near future. 

“We're only 12 months into the journey with this machine, so we have to see how it performs over a longer term. But as we've found with all our electric equipment, the warranty on this machine is double what it is for the diesel machine. So, the manufacturer has confidence that it will deliver long term. And if we need a battery replacement, it's no different than replacing a diesel engine or gearbox.”

 
Mark Darrah, General Manager, Reliance Transport