Total Cost of Ownership: ICE vs EV for Commercial Fleets

Upfront vehicle price is rarely the real problem in fleet decisions. What matters is what vehicles cost to run, maintain, and keep available over several years. This is where total cost of ownership (TCO) becomes the deciding factor, especially when fleets operate at scale. 

In our comprehensive guide on fleet electrification, we looked at why operators are under pressure to electrify their fleets and where the main obstacles sit. This article focuses on the numbers behind those decisions. It compares EV fleet TCO with traditional combustion vehicles and looks at ICE vs EV fleet cost across the areas that matter most to commercial operators. 

The goal is simple: help teams build realistic business cases and have better procurement discussions based on how fleets actually operate. 

What does total cost of ownership mean for commercial fleets? 

For commercial fleets, total cost of ownership reflects how much it costs to keep vehicles available, compliant, and in service over their full operating life. 

This typically covers: 

• Vehicle acquisition or leasing 

• Energy or fuel 

• Maintenance and repairs 

• Charging or refuelling infrastructure 

• Downtime and operational disruption 

• End-of-life value 

Passenger vehicle comparisons often stop at fuel and servicing, but fleet operating costs are broader. Vehicles generate value only when they are available and on the road, which means downtime and inefficiency carry real financial impact. 

How do acquisition and depreciation differ between ICE and EV fleets? 

Electric vehicles often have higher list prices than comparable combustion vehicles, which is why acquisition cost is usually the first objection raised in procurement discussions. On its own, list price is a weak comparison, especially for commercial fleets that rarely buy vehicles in isolation or at retail terms. 

Fleet acquisition works through volume purchasing, leasing structures, and multi-year contracts. Incentives, tax treatment, and financing conditions all influence the effective cost paid over the vehicle’s operating life. In many European markets, electric vehicles benefit from reduced registration taxes, lower company car taxation, or exemptions that apply over several years. These mechanisms do not eliminate upfront cost differences, but they materially change how those costs are spread and recovered. 

Residual value assumptions play a larger role than they did a few years ago. As emissions rules tighten and access restrictions expand, demand for certain combustion vehicles weakens earlier in their lifecycle. Vehicles that face future access limits or higher operating penalties are harder to remarket, which increases depreciation risk. This risk is often underestimated at the point of purchase because it sits several years out. 

Electric vehicles carry different depreciation dynamics. While long-term resale markets are still evolving, regulatory direction provides more certainty around access and usability. Vehicles that remain compliant with emissions and access rules retain operational relevance for longer, which supports residual value assumptions used in fleet financing. 

For procurement teams, this shifts the comparison. ICE vs EV fleet cost cannot be judged at contract signature alone. Acquisition terms, tax exposure, and depreciation risk all interact over time. When these factors are considered together, purchase price becomes one input among several, not the deciding factor. 

How do energy costs compare between ICE and EV fleets? 

Energy is one of the clearest cost differences between combustion and electric fleets, especially once vehicles are used at scale. The difference is not only about price per kilometre, but about how energy is purchased, managed, and controlled. 

Electric vehicles typically have lower energy costs per kilometre than petrol or diesel vehicles. The reason is simple. Electric drivetrains convert a higher share of energy into motion, while combustion engines lose a large portion as heat. Over thousands of kilometres, this efficiency gap translates directly into lower energy spend. 

Predictability is where the difference becomes more meaningful for fleets. Electricity used for depot charging can be procured under fixed contracts, monitored in real time, and scheduled to avoid peak tariffs. Charging during overnight or off-peak periods further reduces exposure to price spikes. Energy consumption per vehicle is also more consistent, which makes forecasting easier. 

Fuel costs behave differently. Prices fluctuate daily and are influenced by factors outside an operator’s control. Refuelling happens during operations, which makes timing harder to optimise. Consumption varies more with driving conditions and vehicle wear, adding uncertainty to cost projections. 

For high-mileage fleets, these effects compound quickly. Small differences in cost per kilometre turn into material budget impacts over several years. When energy spend becomes more predictable, financial planning improves and EV fleet TCO models become more reliable. 

Are maintenance and repair costs lower for electric fleets? 

Maintenance is another area where electric fleets differ significantly. 

Electric vehicles have fewer moving parts. There are no oil changes, fewer mechanical components, and less wear on braking systems due to regenerative braking. This typically leads to lower routine maintenance needs. 

For fleet operators, this reduces workshop time and unplanned repairs. Vehicles spend more time in service and less time off the road. 

Combustion vehicles rely on complex engines and transmissions that require regular servicing. As vehicles age, maintenance costs tend to increase, while this pattern is less pronounced in electric fleets. 

Lower maintenance costs contribute directly to electric fleet ROI, especially in high-utilisation fleets. 

What infrastructure costs should fleets consider when switching to EVs? 

Charging infrastructure is often cited as a hidden cost of electrification but, at the same time, is also one of the most misunderstood. 

Infrastructure costs vary widely depending on site conditions, power availability, and scale. However, these costs are not recurring in the same way as fuel or maintenance. They are capital investments that support multiple vehicles over time. 

Poor fleet electrification planning increases costs. Overbuilding infrastructure or triggering unnecessary grid upgrades can distort TCO calculations. Right-sized infrastructure based on real usage patterns keeps costs under control. 

For combustion fleets, infrastructure costs are often invisible because fuel stations sit outside the balance sheet. These costs are recovered indirectly through fuel pricing rather than appearing as separate line items. 

When infrastructure is accounted for properly, EV fleet TCO comparisons become more accurate. 

How does downtime affect ICE vs EV fleet operating costs? 

Downtime is one of the least visible, yet most expensive, components of fleet operating costs. It rarely appears as a dedicated line item, but it shows up indirectly through missed jobs, delayed routes, overtime, and reduced asset utilisation. 

Electric vehicles often deliver higher uptime because of simpler mechanical systems. Fewer moving parts mean fewer failure points, and routine maintenance takes less time. When charging is integrated into depot operations, vehicles typically start the day fully charged. There is no need to schedule refuelling stops during shifts, which reduces interruptions and keeps routes predictable. 

Downtime in electric fleets is more closely tied to EV charger reliability than vehicle failure. When charging infrastructure is planned and monitored properly, this risk is controlled and visible. Issues are detected early, and vehicles can be reassigned or charging schedules adjusted with minimal disruption. 

Combustion vehicles face a different pattern. Refuelling happens during operating hours and competes with productive time. Mechanical wear increases with mileage, and failures become more frequent as vehicles age. Breakdowns are often unplanned and harder to predict, which disrupts routes, schedules, and service commitments. 

The financial impact of downtime is often underestimated because it is spread across operations rather than booked as a direct cost. Productivity drops. Backup vehicles are required. Staff time is lost to rescheduling and recovery. Over a full vehicle lifecycle, these effects materially influence total cost of ownership and distort comparisons that focus only on fuel, energy, or maintenance. 

How does fleet size affect EV total cost of ownership? 

The cost dynamics between combustion and electric vehicles change as fleet size increases. Differences that look marginal at small scale become material once dozens or hundreds of vehicles are involved. 

Energy savings are one example. A small reduction in cost per kilometre may seem insignificant for a handful of vehicles. Across a large fleet with high annual mileage, it becomes a predictable and recurring budget impact. The same applies to maintenance. Fewer service events per vehicle translate into fewer workshop hours, lower parts inventory, and less operational disruption when multiplied across the fleet. 

Scale also improves visibility. Larger electric fleets generate consistent data on charging behaviour, energy use, and vehicle availability. This data supports optimisation that is difficult in smaller setups. Charging schedules can be refined. Power limits can be managed more precisely. Vehicle utilisation can be balanced across sites. These improvements reinforce cost control over time. 

The downside is that errors scale just as quickly. Overestimating charging demand leads to oversized infrastructure and unnecessary grid upgrades. Fragmented systems create manual work that grows linearly with fleet size. Small inefficiencies that are manageable at pilot stage become structural problems when replicated across locations. 

This is why electric fleet ROI depends less on individual vehicle economics and more on system design. When electrification is managed as an integrated operational setup, scale amplifies the benefits. When it is treated as a series of isolated decisions, scale amplifies the cost and complexity instead. 

What are the most common mistakes in ICE vs EV TCO comparisons? 

ICE vs EV fleet cost comparisons often fail because they are built on assumptions that do not reflect how commercial fleets actually operate. The models look reasonable on paper, but they miss factors that drive real cost over time. 

One common issue is ignoring downtime and operational disruption. Many comparisons focus on fuel or energy spend and scheduled maintenance, while treating availability as a given. In practice, unplanned downtime affects route completion, staff utilisation, and service quality. When this is excluded, combustion fleets often appear cheaper than they are in daily operations. 

Another frequent error is overestimating charging infrastructure needs. TCO models sometimes assume maximum charging power for every vehicle at all times. This inflates infrastructure costs and makes electrification look uneconomical. Real-world charging behaviour is usually more staggered and predictable, which allows infrastructure to be sized more efficiently. 

There is also a tendency to underestimate long-term fuel and maintenance costs for combustion vehicles. Early years look manageable, but costs rise as vehicles age. More frequent servicing, higher failure rates, and fuel price volatility are often discounted or averaged away in models that focus on short time horizons. 

Finally, many comparisons rely on passenger vehicle data. Commercial vehicles operate differently. They drive more kilometres, follow fixed routes, and face tighter uptime requirements. Using consumer assumptions for commercial use cases skews results and weakens business cases. 

Accurate EV fleet TCO models are grounded in operational reality. They reflect how vehicles are used, how charging actually happens, and how maintenance and downtime play out over several years. Without this, comparisons remain theoretical and misleading. 

How should fleets use TCO to support electrification decisions? 

Total cost of ownership (TCO) provides a clearer way to compare combustion and electric fleets. When energy, maintenance, infrastructure, and downtime are included, the cost picture changes. For many commercial fleets, electric vehicles deliver lower operating costs and more predictable expenses over time. 

EV fleet TCO is not identical for every operation. Results depend on mileage, charging access, and planning quality. However, focusing only on purchase price hides the factors that matter most at scale. 

eMabler supports fleet operators in managing the operational side of electrification. Our open EV charging platform helps organisations run and monitor charging infrastructure across sites, manage users and access, and keep charging operations aligned with real fleet needs.  

If you are operating or planning EV charging infrastructure as part of a fleet setup, get in touch with us! We can show how eMabler supports day-to-day charging operations across sites and vehicles.