Electrification Across the Border: DHEMAX and Bali Express Charge Ahead

Project Summary

Bali Express, a leading cross-border logistics and transportation company operating between Mexico and the United States, faced the challenge of increasing the operational continuity of their current electric truck fleet by 50%. The operational context is highly complex, and focused on focused on the operational bases in Tijuana, San Diego, and Long Beach, for extended routes connecting these yards with clients in Los Angeles, the Port of Long Beach, and other key cities in California (USA) and Baja California (Mexico).

The company’s dynamic logistics demand maximum reliability and rapid response times, requiring a rigorous, realistic, and adaptable approach to translate sustainability into tangible operational and economic efficiency. Key challenges include meeting California’s regulations, maintaining logistics efficiency, navigating US-Mexico border restrictions, addressing limited charging infrastructure, and managing the financial costs of transition.

Strategic Objectives

To address these Challenges, Bali Express hired DHEMAX, a leading consultancy firm specializing in electric mobility solutions, for a comprehensive consultancy to address three strategic objectives:

Study the technical and operational feasibility of migrating to electric trucks based on their current use, analyzing potential gaps and proposing solutions.
Design a scalable, efficient, and adaptable charging infrastructure for their current yards.
Determine the progressive migration roadmap for their fleet, optimizing the return on investment.

The DHEMAX Solution

DHEMAX delivered a comprehensive, data-driven solution integrating technical expertise, operational analysis, and strategic planning to guide Bali Express toward confident fleet electrification. They conducted an in-depth assessment of technical, operational, and regulatory gaps through site visits, route observations, and GPS data from eight trucks over 98 days—revealing key patterns in energy use, idle time, and charging opportunities critical to the migration strategy.

A scalable three-phase charging infrastructure plan was designed for 80, 90, and 120 trucks, incorporating split chargers with dynamic load distribution and a DHEMAX-developed Charging Management System (CMS). Two adaptable layout options were proposed for Tijuana to support future fleet growth.

Finally, DHEMAX produced a phased investment roadmap pinpointing which routes could be electrified immediately and which required additional infrastructure or partnerships—balancing risk and transition speed. The analysis also uncovered a strategic charging location that revived a previously unviable route, showcasing how expert insights can unlock hidden operational opportunities.

Timeline

Oct/ 2024

Project Start – Comprehensive consultancy begins with operational characterization.
Nov/ 2024

Route definition and case study development based on GPS data analysis.
Dec/ 2024

Feasibility analysis using real consumption data from 98 days of operation.
Jan/ 2025

Infrastructure design and energy demand projection.
Feb/ 2025

Roadmap development and financial analysis.
Mar/ 2025

Project End – Delivery of feasibility analysis, infrastructure design, and migration roadmap.

Project Result: Fleet Migration Roadmap

Phase 1

(Short term) – Migration of 80 trucks to local and short cross-border routes. Use of infrastructure in San Diego.

Phase 2

(Mid-term) – Expansion to 90 trucks, with implementation of infrastructure in Tijuana.

Phase 3

(Long-term) – Expansion to 120 vehicles in the San Diego – Tijuana area and incorporation of additional vehicles in the San Diego – Long Beach sections with infrastructure extension and strategic alliances.

Phase 4

(Very Long-term) – Start of electrification of long routes (>300 miles), using shared infrastructure with other operators in areas such as Long Beach or San Bernardino.

Who Was Involved

DHEMAX– DHEMAX, a consultancy specializing in electric mobility, fleet electrification, and charging infrastructure, delivered a comprehensive feasibility study, scalable charging design, fleet migration roadmap, and strategic charging opportunities. Its proprietary Charging Management Systems (CMS) and fleet monitoring tools optimize battery life and ensure operational compliance.
Bali Express – A leading cross-border logistics and transportation company between Mexico and the United States, operating key routes in California and Baja California. Bali Express is committed to transitioning to a 100% electric fleet to meet regulatory requirements and sustainability goals.

Lessons Learned

Right-sizing and Customization

It is not necessary to acquire vehicles that can complete the total daily range on a single charge. The available times during the operational shift allow for intermediate recharges sufficient to cover the energy requirements. DHEMAX analysis demonstrated that opportunity charging during operational pauses (such as border crossing wait times) can effectively extend vehicle range without impacting productivity.
Cost-Effectiveness of a Right-Sized Fleet and Charging

The cost of acquiring a vehicle with a longer range is significantly greater than the operational cost of daytime charging. The price difference for a fleet of 30 vehicles could cover the cost of infrastructure installation and the additional cost of peak-hour charging for up to 10 years of operation if the more economical, lower-range vehicle is chosen. DHEMAX calculated savings of USD $50,000 per truck, totaling USD $1.5 million for a 30-truck fleet.
Fleet Management as a Key Enabler

A fleet management strategy allows for the projection of vehicle energy requirements and the proper programming of charging sessions to optimize battery life and ensure operational compliance. DHEMAX proprietary CMS enables real-time monitoring and predictive charging scheduling, reducing battery degradation and maximizing vehicle availability.
Data-Driven Decision Making

DHEMAX methodology relies on real operational data rather than theoretical models. By analyzing 98 days of GPS data and actual energy consumption patterns, DHEMAX identified a 20% additional energy consumption during idle periods (particularly during border crossing wait times). This finding was critical to accurately sizing the charging infrastructure and ensuring operational reliability.
Revenue Generation and Replicable Model

The installation of proprietary infrastructure allows for commercial alliances with other fleet operators and the provision of energy to third parties during hours of lower use. The infrastructure and planning can be applied in other yards or replicated in new markets, creating additional revenue streams beyond operational savings.
Vehicle Selection Must Be Client-Specific

Sotraser has proven the importance of matching vehicles to client needs. For some customers, Foton trucks offer an affordable option, while for others, Mercedes trucks provide greater range despite higher upfront costs. By balancing these trade-offs, Sotraser ensures clients receive tailored solutions that align with both operational demands and sustainability goals. Their adaptability reinforces their role as a trusted, forward-thinking logistics partner.

Key Results

Validated Feasibility: 50% of the fleet can be electrified with current trucks without affecting operations, and an additional 20% could migrate in the mid-term.
Significant Savings: USD $50,000 per truck, with total savings of USD $1.5 million for a 30-truck fleet.
Scalable Infrastructure: Design for 3-stage growth (80 → 90 → 120 trucks) with minimal additional investment.
Strategic Charging Point: Identification of a new charging location that recovered a previously non-viable route.
Real Data Analysis: 98 days of operational data analyzed, identifying 20% additional energy consumption during idle periods.
Revenue Generation: Infrastructure design enables commercial alliances and energy provision to third parties.
Replicable Model: Infrastructure and planning can be applied in other yards or replicated in new markets.

Project Summary

Strategic Objectives

Study the technical and operational feasibility of migrating to electric trucks based on their current use, analyzing potential gaps and proposing solutions.

Design a scalable, efficient, and adaptable charging infrastructure for their current yards.

Determine the progressive migration roadmap for their fleet, optimizing the return on investment.

The DHEMAX Solution

Timeline

Oct/ 2024

Nov/ 2024

Dec/ 2024

Jan/ 2025

Feb/ 2025

Mar/ 2025

Project Result: Fleet Migration Roadmap

Phase 1

Phase 2

Phase 3

Phase 4

Who Was Involved

Lessons Learned

Right-sizing and Customization

Cost-Effectiveness of a Right-Sized Fleet and Charging

Fleet Management as a Key Enabler

Data-Driven Decision Making

Revenue Generation and Replicable Model

Vehicle Selection Must Be Client-Specific

Key Results

Further Reading

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