On-Board vs Stationary Charging: A Comprehensive Breakdown

The transition from internal combustion to electrified powertrains raises many questions. Where refueling once hinged on liquid fuel logistics, modern OEMs must now answer a more complex query: How will your machines charge, and where?

As part of the Future of Electrification 2025 conference, Marco Sabatini, Key Account Manager at ZIVAN, and Mourad Chergui, Senior Product Manager at Delta-Q Technologies, discussed the options available in the webinar “Material Handling Equipment Battery Charging Trends”.

From legacy OEMs seeking to embrace the electric transition to fleet managers grappling with logistical charging challenges, this discussion offers critical guidance in selecting the optimal solution.

Overview of the Charging Ecosystem

Advancements in lithium-ion and next-generation chemistries eliminated many of the inefficiencies that once constrained electric fleet operations. 

For fleet managers, the answer to slow recharge times is no longer to simply purchase more vehicles. Rather, the answer lies in smarter charging systems to maximize uptime for what they already own.

To accomplish that objective, two primary architectures shape today’s charging strategies:

• On-board chargers offer unmatched versatility, enabling vehicles to draw power from a wide range of sources. However, their integration must account for constraints such as space, weight, and thermal management within the vehicle design.
• Stationary chargers deliver higher power levels, enabling rapid recharging and minimizing downtime. These units, however, demand dedicated infrastructure, physical space, and careful planning to ensure compatibility with facility operations.

Clearly, each approach introduces unique advantages and limitations. 

Selecting the right system requires thoughtful evaluation of the operational environment, fleet composition, and long-term scalability goals.

On-Board Chargers: Facilitating Fleet Flexibility

While off-board chargers historically dominated industrial installations, modern advancements in on-board systems deliver critical advantages in more decentralized and mobile environments.

Consider a few key benefits of on-board chargers in greater depth:

• Operational flexibility – With charging hardware and communication protocols built into the vehicle, machines can refuel anywhere compatible infrastructure is available—whether at a remote job site using AC power or at a public EV charging station—eliminating dependency on fixed locations.
• Streamlined integration – OEMs and operators can transition to electric fleets without major upfront infrastructure investments. This is particularly valuable in facilities lacking space, capital, or permitting capacity for dedicated charging bays or power upgrades.
• Reduced downtime – On-board systems enable quick top-ups during natural pauses—whether shift changes, meal breaks, or idle periods—to enable multi-shift operations without disrupting workflows.
• Embedded safety – Integrated safeguards such as overvoltage, short circuit, thermal monitoring, and fault detection enhance charging safety without requiring external intervention or site-specific systems.
• Enhanced battery oversight – Direct communication with the vehicle’s battery management system (BMS) allows on-board chargers to dynamically optimize voltage, current, and temperature during every charging session, prolonging battery life and improving performance consistency.

On-board chargers thus suit verticals such as construction, where agility and distributed operations outweigh the need for ultra-fast recharge cycles. 

Even stationary operations stand to benefit. For example, warehouse managers swapping from stationary infrastructure to on-board solutions could repurpose charging rooms into spaces that promote direct revenue-generating activity.

Stationary Chargers: Stable Solutions for Steady Power

Despite all the advantages of on-board chargers, they are not a perfect solution. Charging speed constraints, while one of their few drawbacks, can be a dealbreaker depending on the nature of the application. 

For such operations, stationary chargers remain a cornerstone of electrification strategy. Their advantages can be summarized as follows:

• Higher charging power – With higher voltage and amperage levels, stationary systems deliver more power than their on-board counterparts. This enables rapid battery replenishment for demanding duty cycles.
• Simplified thermal management – Unlike mobile solutions that must operate in harsh environmental conditions, stationary units are easier to manage thermally due to their dedicated cooling systems. 
• Reduced vehicle weight – Offloading the charger to a fixed location removes bulk and complexity from the vehicle itself. This reduces weight, frees up internal space, and potentially lowers production costs for heavy-duty machinery.

Stationary charging solutions excel in fixed-location environments such as distribution centers, where fleet movements are predictable and space allows for dedicated charging zones.

Bridging the Gap: Hybrid Approaches and Modular Solutions

Much as lithium-ion technology redefined the parameters of fleet efficiency, recent innovations in charging architecture reshape how (and where) electric machinery receives power. Distinctions between on-board and off-board chargers are no longer a binary choice.

Rather, the emergence of hybrid systems unifies the strengths of both.

Thanks to modular, software-defined charging architectures, OEMs no longer need to choose between flexibility and performance. Consider ZIVAN’s SG9 system as an example: 

• Derived from the field-tested and OEM-awarded SG3 on-board charger, ZIVAN’s SG9 reimagines the same platform in a compact, mobile off-board configuration.
• Delivering up to 9 kW of power, the SG9 unit is purpose-built for low-voltage machinery requiring rapid turnaround—without the footprint of permanent infrastructure.
• Designed with ruggedized mobility in mind, the SG9 brings reliable, high-efficiency charging to remote job sites, fleet hubs, and anywhere else traditional infrastructure may fall short.
• Advanced charging algorithms, typically a feature associated with vehicle-integrated systems or dedicated infrastructure, are customizable to every SG9—maximizing battery performance while preserving space onboard the vehicle.

This convergence paves the way to increased strategic flexibility. 

By leveraging an on-board foundation within an off-board framework, the SG9 offers OEMs a powerful, modular alternative to costly fixed installations or burdensome on-board systems.

ZIVAN: Charging Solutions for OEM Verticals

As battery chemistries evolve and global charging standards mature, selecting the right charging architecture likewise evolves from a technical question into a strategic one. Tailored, optimized chargers define long-term efficiency, scalability, and return on investment.

And that is precisely what ZIVAN delivers.

ZIVAN’s portfolio of high-frequency chargers, modular off-board platforms, and vertically-tailored solutions equips OEMs with a sustainable electrification framework, engineered for the unique demands of each application.

Backed by the collective expertise of the ZAPI GROUP, every ZIVAN solution is supported by decades of electrification experience, global supply chain resilience, and system integration capabilities. ZIVAN ensures unerring performance—from design to deployment.

To find out more, watch the full webinar, or reach out to ZIVAN expert Marco Sabatini to discuss your electrification project today. 
Marco Sabatini email: marco.sabatini@zivan.it

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Violetta Fulchiati | Marketing & Communication Specialist 
Phone: +39 0522 960593
E-mail: marketing@zivan.it