By Steve Ratcliffe, Global Product Manager, Powerfleet

The transition to zero-emission commercial vehicles is well underway across the US and Europe, with much attention focused on electrifying last-mile delivery vans in urban environments. While this progress is commendable, a significant gap in the conversation urgently needs to be addressed: the unique sustainability challenges that utility fleet operators face.

Utility companies maintain some of the country’s largest Light Commercial Vehicle (LCV) fleets. These vehicles undertake some of the most challenging tasks, navigating off-road terrain and carrying specialized equipment. They often support critical infrastructure maintenance and repairs at a moment’s notice. The current drive toward electrification has left these essential fleets with limited viable options in their sustainability journey.

The Utility Fleet Reality

Utility companies’ transition to alternative fuels presents distinct challenges that differ markedly from those of standard delivery operations. Their vehicles must meet specific operational demands that many current electric LCVs simply can’t satisfy.

Utility workers often require a greater range than most electric vans, particularly when operating in areas with minimal charging infrastructure. Weight restrictions become problematic when considering the heavy, specialized equipment and tools these vehicles carry. The need for 4×4 capability is non-negotiable when accessing remote areas, yet the current EV market provides few viable options in this category.

Add to this the requirements for durability in harsh conditions, substantial towing capacity, and the high initial cost of upfitting suitable vehicles, and you begin to understand why many utility fleet managers feel overlooked in the push toward zero-emission deadlines.

Data Fragmentation: A Major Obstacle

Beyond the vehicle challenges, utility fleet operators face another significant barrier to effective sustainability management: fragmented data.

Currently, many fleet operations resemble a chaotic traffic circle where data enters from various sources and exits just as quickly in different directions. A typical utility fleet might collect information from telematics systems, fuel cards, maintenance records, driver behavior monitoring, and charging infrastructure – all in separate systems that often don’t communicate with each other.

This disconnected approach makes it almost impossible to gain a comprehensive view of sustainability metrics or make informed decisions about adopting alternative fuels. How can fleet managers confidently invest in new technology without a clear picture of their current operations and the potential impact of changes?

A Holistic Approach to Utility Fleet Sustainability

The path forward requires vehicle manufacturers and technology providers to recognize the specific needs of utility fleets and develop solutions accordingly.

For vehicle manufacturers, this means creating fit-for-purpose electric and alternative fuel options that meet the demanding requirements of utility operations. These vehicles should have adequate range, 4×4 capability, appropriate payload and towing capacity, and the durability to withstand harsh working conditions, all at a reasonable cost.

For technology providers like Powerfleet, this means transforming that chaotic traffic circle into something more like a highway – with everything moving in the same direction, clearly marked entrances and exits, and every vehicle interacting seamlessly at speed.

Our Unity platform represents this vision in action, consolidating disparate data sources to provide comprehensive fleet intelligence. Integrating telematics, maintenance records, fuel data, and sustainability metrics into a single ecosystem enables utility fleet managers to make genuinely informed decisions about their transition to alternative fuels.

This consolidated approach allows operators to identify which routes and vehicle types are suitable for immediate electrification, where hybrid solutions might be more appropriate, and where investment in more efficient internal combustion engines might be the best interim strategy.

Future-Proofing Utility Fleets

The reality is that commercial fleets span diverse sectors beyond last-mile delivery, each with specific operational demands. Utility companies, with their need for specialized vehicles, require tailored sustainability solutions rather than a one-size-fits-all approach.

Now more than ever, it is essential to develop comprehensive testing strategies that help operators make informed decisions about selecting electric LCVs based on their specific operational requirements.

By consolidating data sources, enabling informed decisions about alternative fuel adoption, and advocating for suitable vehicle options, we can help utility fleet operators navigate the complex journey to sustainability without compromising operational effectiveness.

The industry must recognize that while last-mile delivery represents the most visible and viable segment of the ELCV market, sectors like utilities require equal attention and specialized solutions to achieve the broader sustainability targets. Only by addressing these overlooked challenges can we ensure that all commercial fleets – not just the most visible ones – are prepared for a sustainable future.

Are you ready to overcome your utility fleet’s sustainability challenges? Contact Powerfleet today for tailored solutions that meet your specific operational needs while advancing your environmental goals.

Transitioning to sustainable fleet operations presents unique challenges across different industries, particularly in sectors like utilities, where specialized vehicles are essential. We’re excited to announce that Steve Ratcliffe, our Global Product Manager, has joined Fleet Europe’s Commercial Fleets Advisory Board, bringing his extensive expertise in sustainable fleet operations and data management to help shape the industry’s future.

With over three decades of experience in vehicle data and fleet operations, Steve brings a unique perspective on the challenges and opportunities in sustainable fleet management, particularly in the utilities sector. His appointment to the advisory board highlights Powerfleet’s commitment to fostering sustainable innovation in the light commercial vehicle (LCV) sector through advanced AIoT solutions.

“The LCV sector faces significant challenges as we move toward zero-emission deadlines,” says Ratcliffe. “Utility companies, in particular, need specialized vehicles that can navigate demanding terrain and conditions, yet the current EV market provides limited options to meet their needs. Factors such as range, weight restrictions, 4×4 capability, durability, towing capacity, and the initial cost of vehicles must all be considered.”

Transforming Fleet Data Management for Sustainable Operations

One key challenge in transitioning to sustainable fleet operations is effective data management. Steve’s vision for transforming this aspect of fleet management aligns perfectly with our innovative Unity ecosystem: “Currently, we appear to be at a roundabout where data comes in from various sources and exits just as quickly in different directions. Through Unity, Powerfleet’s vision is more like an autobahn, with everything going in the same direction, clearly marked entrances and exits, and every vehicle interacting at speed.”

This vision is particularly crucial as organizations work to track and improve their sustainability metrics. Our Unity ecosystem addresses this challenge head-on by consolidating fragmented data sources into actionable insights, enabling better decision-making and comprehensive sustainability tracking.

Recently, ABI Research, a leading provider of data-driven market intelligence, validated the strength of our innovative approach by ranking Powerfleet #1 globally for innovation among commercial solution providers for mobile assets. ABI Research specifically noted that “Powerfleet led the innovation rankings thanks to its comprehensive Unity platform and the range of its cutting-edge solutions, which have positioned it as a leading AIoT player.”

A Proven Track Record in Sustainable Fleet Transformation

Before joining Powerfleet, Steve demonstrated his commitment to sustainable fleet transformation by leading the integration of multiple telematics systems to enhance preventative maintenance across utility sector fleets, managing a baseline of over 185,000 vehicles. He also developed comprehensive EV test strategies to help fleet operators make informed decisions about selecting electric LCVs.

“While much of the industry concentrates on last-mile delivery solutions, the truth is that commercial fleets span diverse sectors, such as utilities, oil and gas, and mining – each with specific operational demands,” notes Ratcliffe. “Through Unity and our other AI-powered solutions, we’re helping organizations future-proof their operations by consolidating disparate data sources, enabling informed decisions about alternative fuel adoption, and ensuring they have the right vehicles and technologies for their specific needs.”

Collaborating for a Sustainable Future

The Fleet Europe Commercial Fleets Advisory Board unites business leaders and decision-makers from various industry disciplines to foster collaboration and share best practices in the LCV ecosystem. “The makeup of this advisory board, which brings together vehicle equipment manufacturers, energy providers, and fleet operators, creates an ideal forum for addressing these complex challenges collaboratively,” says Ratcliffe.

The advisory board focuses on three key missions: exploring new business opportunities, strengthening the LCV fleet management community, and sharing expertise to enhance industry initiatives.

As we continue to innovate and develop solutions for sustainable fleet operations, Steve’s participation on the Fleet Europe Advisory Board represents an exciting opportunity to collaborate with industry leaders and drive positive change in the commercial fleet sector.

Together, we’re working to create a more sustainable future for fleet operations across all industries.

The UK government recently unveiled its ambitious AI Opportunities Action Plan. Prime Minister Keir Starmer emphasized AI’s ‘vast potential’ to transform public services and working lives. One area that stands out is workplace safety and operational efficiency. While much of the conversation focuses on future possibilities, AI is already transforming how organizations protect workers and optimize operations.

At Powerfleet, we see this transformation firsthand across our network of over 48,000 customers. Companies are moving beyond traditional safety protocols to embrace AI-driven systems that unify data from hundreds of IoT devices and sensors. This isn’t about future potential — it’s about real solutions that deliver measurable improvements in workplace safety today.

What makes these AI-driven insights genuinely transformative? How are industry leaders using these technologies to create safer, more efficient workplaces?

Current state of workplace safety challenges

According to Safe Work Australia, the transport, postal, and warehousing industries in Australia recorded the highest number of workplace fatalities in 2024, with 48 lives lost. This sector also accounted for over 10,000 serious injury claims, reflecting a concerning trend in workplace safety. Total workplace injuries across all industries increased from 130,000 in 2020 to 140,000 in 2024, underscoring the urgent need for action.

In 2022, the transportation and warehousing sector in the US reported a serious injury rate of 3.8 cases per 100 workers, primarily due to incidents involving overexertion. Furthermore, the manufacturing sector in Canada has experienced a 120% increase in injury-related costs since 1997. Compounding the issue, worker turnover in Canadian warehouses reached 49% in 2021, making retention efforts more difficult amid rising demand for skilled labor as warehouses expand.

AI-driven solutions in action

Real-Time Hazard Detection
Powerfleet’s Vision AI and Pedestrian Proximity Detection (PPD) are pioneering ways to prevent accidents in high-risk environments, both on the road and in the warehouse. Vision AI uses AI-enabled dashcams to monitor driver behavior, identifying fatigue and risky actions like using a mobile phone or changing lanes without signaling. These insights enable immediate corrective actions, reducing the likelihood of accidents.

Similarly, Pedestrian Proximity Detection systems identify potential collisions between industrial vehicles like forklifts and pedestrians in real time. Unlike traditional tag-based solutions, PPD ensures universal safety across the workplace by automatically slowing vehicles, alerting operators, and notifying nearby workers. This proactive technology transforms how organizations manage hazards, making prevention a priority.

Unified Data Insights
AI excels in interconnected systems, and Powerfleet’s Unity platform is a prime example of this capability. Unity leverages AI and machine learning to effectively monitor and manage assets, vehicles, and personnel by collecting data from any IoT device, OEM system, or external source.

Key integrations include:

• Forklift Gateway Integration: Pedestrian Proximity Detection and Digital Video Recorders (DVRs) capture data on breach locations, driver identification, and near-miss incidents. These insights help businesses pinpoint high-risk areas and implement targeted safety measures.
• Real-Time Monitoring: AI tools ensure constant oversight by recording activities before, during, and after incidents. DVRs, for example, provide a holistic picture of workplace dynamics, enabling swift and effective responses to safety events.

This unified approach empowers organizations to identify inefficiencies, reduce risks, and improve safety and operational performance.

Predictive Safety Measures
Powerfleet’s AI-driven solutions go beyond reactive safety. They use data to predict and prevent risks. By analyzing driver behavior, historical trends, and operational patterns, these tools enable businesses to adopt preventative measures such as targeted driver training and tailored safety protocols.

For example, Vision AI helps fleet managers proactively monitor road conditions and vehicle performance, addressing potential risks before they escalate. Similarly, insights from Pedestrian Proximity Detection highlight high-risk areas and near-miss incidents, allowing for continuous optimization of safety measures. These predictive capabilities enhance workplace safety, reduce downtime, and drive long-term cost savings.

The Future of AI in Workplace Safety

As the UK accelerates its AI initiatives, the material handling and fleet management industries stand at a crucial intersection of safety and innovation. While autonomous solutions are on the horizon, the immediate focus must be on leveraging AI to enhance current operations and protect today’s workforce.

PowerFleet’s integrated approach—combining Vision AI, Pedestrian Proximity Detection, DVRs, and our Unity platform—bridges present needs and future capabilities. These solutions prevent accidents and lay the groundwork for the next evolution in workplace safety, where real-time data fuels proactive decision-making.

This transition period offers unique opportunities. Organizations implementing AI-driven safety systems today gain immediate benefits while building the technological infrastructure and operational expertise needed for future innovations.

The key is understanding that safety transformation isn’t about waiting for full automation—it’s about taking strategic steps now to protect workers, enhance efficiency, and get ready for tomorrow’s challenges.

Learn more about our AI-powered solutions and how we can help you improve safety and efficiency at your organization.

As the industry moves toward automation, protecting today’s workforce requires immediate action through advanced safety solutions.

By Scott Walker, VP Supply Chain Product Management at Powerfleet

In a recent article, The Wall Street Journal (WSJ) highlighted a sobering reality: forklift-related incidents continue to cause nearly 100 deaths and over 7,500 injuries each year, prompting manufacturers to seek alternatives, including autonomous solutions. While this automated future is promising—and in some facilities, it is already taking shape—most businesses worldwide still depend on traditional forklifts. The challenge facing the industry is clear: How do you protect your workforce now while preparing for the transformative changes ahead?

The Persistent Challenge of Forklift Safety

The stark statistics reported by the WSJ highlight what regulatory bodies worldwide have long underscored: ineffective training and minimum safety measures continue to be key factors in forklift-related incidents. Various agencies—from OSHA in the U.S. to the HSE in the U.K., as well as safety regulators throughout Europe, Africa, and Australasia— emphasize the critical importance of proper safety protocols but leave the approach to individual businesses.

In the U.S. alone, OSHA issues approximately 2,000 citations each year for insufficient forklift safety training, while global organizations confront similar penalties and legal consequences for failing to safeguard their workforce.

The impact on operations extends far beyond regulatory compliance. When employees feel unsafe, turnover rises, morale dips and operational output suffers. It’s a lose-lose scenario that no business—regardless of size—can afford to ignore.

The Promise of Autonomous Solutions

Undoubtedly, autonomous forklifts and robotic material carriers are shaping the future of material handling. These cutting-edge innovations promise fewer incidents involving human operation, more efficient workflows, and minimized downtime. As the article in The Wall Street Journal points out, early adopters like Whirlpool have already realized tangible benefits, observing significant reductions in injuries after implementing autonomous solutions.

However, it is important to recognize that we are in a transitional period. Most warehouses, factories, and logistics hubs still rely heavily on manual forklift operations. For certain industries or regions, complete autonomy may be five to ten years away. In the meantime, maintaining a razor-sharp focus on safety today is essential to protecting your workforce and ensuring compliance.

Optimizing Current Fleet Safety

While the concept of an autonomous fleet is exciting, it doesn’t necessarily help you maximize your current forklift investments. Many organizations cannot completely replace their existing fleets overnight. This is where integrating advanced safety technologies with your current assets yields significant benefits and ROI.

At Powerfleet, we focus on safety-driven solutions that help close this gap. Our AI-enabled pedestrian proximity detection and SaaS-based forklift telematics provide real-time data on operator behavior, equipment status, and potential collisions—ultimately reducing incidents, downtime, and liability. By adding these innovative solutions to your existing forklifts, you won’t have to wait years to enjoy the benefits of next-gen safety.

Beyond Compliance: Proactive Safety Leadership

Our partnerships with leading operations worldwide have taught us that effective safety management necessitates advanced technology and cultural transformation. A common oversight involves treating safety as merely a reactive measure, a series of checklists, and compliance steps.

In reality, proactive safety management encompasses:

1. Real-Time Monitoring: Drivers and supervisors receive immediate alerts that safety risk increases beyond acceptable thresholds, enabling on-the-spot coaching.
2. Operator Accountability: Detailed data on vehicle or asset usage allows organizations to incentivize safe driving and operating behaviors and quickly address risky ones without negatively affecting output.
3. Targeted Training: Leveraging AI-driven insights to customize training programs for real challenges.
4. Data-driven Change: Trend and benchmark analysis on vehicle health, risky operators, and the highest-risk areas of the facility by the time of day allow effective decisions on facility and personnel changes to foster a safer environment.

Leading the Safety Evolution

The autonomous revolution in material handling is already starting to reshape the industry. While robotic pallet jacks and advanced guided vehicles are entering high-tech facilities, the transformation will be gradual and varied across different operations. This evolution presents both an immediate challenge and an unprecedented opportunity.

Success in this transitionary period requires a dual focus:

1. Implement advanced safety solutions to protect people and assets, creating immediate returns on your fleet investments.
2. Build the technological foundation and operational expertise to enable seamless integration of autonomous solutions as they mature.

By prioritizing safety today, organizations fulfill their immediate regulatory requirements and foster more stable, efficient operations. Most importantly, they cultivate an engaged, safety-conscious workforce, which is crucial for navigating the technological evolution ahead.

The future of material handling promises unmatched safety and efficiency through automation. However, the foundation for that future and the protection of today’s workforce depend on the strategic choices industry leaders make now.

About Powerfleet

Powerfleet is a global leader in material handling telematics and AI-driven safety solutions. Our end-to-end platforms enable businesses to gain real-time visibility, reduce risk, and maximize ROI on their current forklift fleets while preparing them for the autonomous future.

Ready to boost your safety initiatives and consult with us—regardless of where you stand in your automation journey? Let’s connect.

Reach out to discover how our solutions can help protect your workforce and improve your bottom line today while establishing a foundation for a safer, more efficient tomorrow.

The health and longevity of your assets and vehicles are crucial to your operation. Without proactive maintenance, real-time diagnostic details, and actionable driver performance insights, you risk costly downtime and dissatisfied customers.

Powerfleet offers purpose-built solutions to extend the life of your vehicles and optimize your resources, ensuring your fleet remains a competitive asset. Below, we’ll explore how Powerfleet’s innovative solutions can reduce clutch wear, maintain batteries, manage air suspension, and monitor fault codes effectively.

Innovative Maintenance Strategies for Cost Reduction

Data-Driven Driver Performance Optimization

Livestream data from Powerfleet’s Unity solution empowers fleet managers to enhance driver coaching and performance. Reducing incidents on the road and in the warehouse can significantly decrease costs. Our driver performance insights allow you to incentivize safe driving, identify areas for improvement, and optimize workforce productivity—all while keeping operational costs low.

Predictive Maintenance for Extended Vehicle Life

Managing maintenance based on real-world usage is vital to extending the lifespan of your resources. With Powerfleet’s preventative maintenance capabilities, you can minimize downtime and avoid costly repairs. Real-time engine diagnostics and planned maintenance alerts ensure you stay ahead of potential issues, reducing wear and maximizing vehicle uptime.

Advanced Vehicle Monitoring Features

Clutch Performance Tracking

Clutch wear can lead to costly replacements and unexpected downtime. Powerfleet’s solutions offer valuable data to track clutch usage patterns. Fleet managers can use this information to coach drivers on smoother operations and schedule maintenance before significant wear occurs. This proactive approach ensures operational continuity and reduces unnecessary expenditures.

Battery Health Management

Battery issues are a leading cause of unexpected breakdowns. With Powerfleet’s solutions, you can access real-time battery health indicators, such as voltage levels and temperature fluctuations. Immediate alerts empower fleet managers to address issues before they lead to downtime, ensuring assets and vehicles are always ready for service.

Air Suspension System Optimization

A well-maintained air suspension system reduces component wear and improves fuel efficiency. Powerfleet’s capabilities enable fleet managers to monitor pressure levels, detect leaks, and ensure system integrity. Real-time alerts help address potential issues quickly, enhancing ride quality and reducing long-term repair costs.

Monitoring Fault Codes

Vehicle fault codes offer early warnings for a variety of issues. Powerfleet’s solutions capture these codes in real time, enabling fleet managers to address problems quickly and prevent significant failures. By focusing on real-world diagnostics and data insights, you can prioritize repairs, optimize maintenance schedules, and minimize downtime.

Maximizing Fleet Efficiency Through Data Insights

Dormancy Analysis for Operational Efficiency

Dormant vehicles are a sign of fleet inefficiency. Powerfleet offers visibility into vehicle usage, allowing fleet managers to identify dormant assets and optimize resource allocation. Data-driven decisions improve fleet operations and ultimately enhance your bottom line.

Seamless Third-Party Platform Integration

Powerfleet’s Unity ecosystem integrates seamlessly with third-party platforms, including billing systems, enabling comprehensive asset management. Uniting data from diverse sources streamlines maintenance scheduling and delivery performance reporting processes, ensuring your entire fleet operates efficiently and precisely.

Driver Performance Enhancement

Boost Productivity and Safety

Powerfleet’s solutions allow you to optimize driver performance by continuously monitoring and ranking drivers. Our driver profile capabilities and scorecards provide actionable insights to improve safety, reduce operational inefficiencies, and encourage good driving habits. Optimizing driver behavior impacts asset longevity, reduces operational costs, and enhances customer satisfaction.

Achieving Sustainability Goals

Supporting Your Green Agenda

Powerfleet’s solutions are built to support your sustainability initiatives. By ingesting, processing, and enriching environmental, social, and governance (ESG) data from IoT devices and third-party systems, we enable you to track and achieve your sustainability goals while optimizing operations.

Transform Your Fleet Operations Today

Powerfleet’s purpose-built solutions empower you to maximize asset and vehicle longevity through real-time diagnostics, proactive maintenance, and actionable data insights. By reducing downtime, managing maintenance based on real-world usage, and enhancing driver performance, you can achieve greater fleet efficiency, reduce costs, and improve customer satisfaction.

Ready to optimize your fleet maintenance and performance? Learn more about our Maintenance and Performance solutions.