Electrifying a fleet is no small feat. For OEMs and fleet managers, making this swap demands a shift in both machinery and mindset. As internal combustion engines give way to battery-driven architectures, the logistical demands of large-scale charging must evolve in tandem.
ZIVAN, a ZAPI GROUP company, offers a comprehensive solution: Recharge Rooms.
Designed to bring clarity to the complexities of battery charging, recharging rooms provide a fully integrated, centralized charging infrastructure. Engineered for optimal battery utilization and streamlined maintenance cycles, this revolutionary ecosystem promises to eliminate the inefficiencies often associated with fleet electrification.
As part of the Future of Electrification 2025 conference, Application Engineer Matthew Moore explored this subject in depth during the webinar, “Charging Ahead: Adapting to Emerging Battery Chemistries.”
Moore’s insights outlined how tailored charging solutions—such as the ZIVAN Take-Me system—can serve as a critical enabler for OEMs and fleet managers navigating the electrification journey.
Inside the Recharge Room: A Platform for Scalable Electrification
The Recharge Room is an intelligent infrastructure solution, purpose-built for OEMs and fleet operators managing electrified machinery. Each installation is modular and fully customizable, developed in direct consultation with the customer’s operational environment.
Fundamental capabilities include:
- First-in-first-out (FIFO) sequencing, ensuring balanced battery utilization across the fleet
- Integrated maintenance and substitution logic, enabling uniform performance and predictable replacement cycles
- Battery life optimization, achieved through intelligent charging profiles tailored to each system and battery chemistry
ZIVAN manages the entirety of the installation, meaning there is no need for third-party integrators. The result is a turnkey solution—intelligently designed and expertly deployed in line with exacting OEM requirements.
The Two Varieties of Recharge Rooms
Whether supporting a singular warehouse or an international logistics hub, ZIVAN’s Recharge Room solutions scale to meet the application. There are two core configurations that define the portfolio.
#1. Take-Me System: Smart FIFO for Smaller Fleets
Ideal for small to mid-sized fleets, the Take-Me System coordinates battery availability through a centralized control interface.
Capable of managing up to 20 charging stations, the system offers:
- Visual readiness cues via illuminated indicators
- Standardized charger connections, simplifying pickup
- Unique charger identification for traceability and diagnostics
- FIFO logic to ensure batteries are discharged and charged in rotation
- Up to 7 preset charging profiles, including a fully customizable option
Essentially, this system allows for ongoing charge management while indicating which battery should be picked up next. This queueing allows for an even spread of battery use across the fleet, enhancing uniformity and predictability for maintenance and other needs.
#2. Brain System: Scalable Charge Management Solution
Engineered for industrial-scale operations, the Brain System enables fleet managers to oversee hundreds of charging units from onsite or remote PCs.
Operating across local area network (LAN) architecture, the Brain System consists of a proprietary software suite and dedicated control cabinet equipped with:
- Modem and router
- Integrated UPS (uninterruptible power supply)
- Remote monitoring and diagnostics functionality
- Programmable charging parameters and schedules
- Custom profiles based on battery chemistry, charge history, or time of day
The system is compatible with all major battery chemistries and enables real-time state-of-health (SOH) assessments, ensuring that each charge is optimized to extend battery performance and minimize downtime.
In tandem with the Brain software, connected PCs can log and archive detailed charging data across the fleet. Each charge cycle, assessment, and parameter adjustment is recorded, creating a historical dataset that fleet managers can analyze to inform strategic decisions.
Strategic Advantages of ZIVAN Recharge Rooms
More than a means to distribute power, Recharge Rooms serve as a strategic layer in fleet management. Their benefits cascade across operational and financial dimensions, with ZIVAN customers noting several distinct advantages:
- First-in-first-out charging – Automated FIFO logic via the "Take-Me" system optimizes battery usage across the entire fleet—ensuring even wear, predictable performance, and fewer maintenance surprises.
- No need for third-party integrators – The system is fully proprietary and plug-and-play within ZIVAN’s ecosystem. That translates to faster setup, lower integration costs, and fewer compatibility risks.
- Prolonged battery life – Intelligent battery rotation, SOH assessments, and programmable charge profiles ensure batteries are neither overused nor undercharged—significantly extending their useful life.
- Improved fleet productivity – Remote-ready charging, centralized maintenance scheduling, and unified software control reduce downtime, keep equipment in rotation, and streamline maintenance workflows.
- Actionable data insights – Calculating efficiency at a systemic level—from the battery to the charger to the equipment itself—is nearly impossible without data logging. The cloud-based Recharge Room delivers an intuitive visualization of key data points, empowering fleet managers to develop simulations and make educated calculations on recharge needs.
These advantages become even more pronounced when paired with ZIVAN’s modular “Brain” hardware portfolio, delivering tailored charging and actionable intelligence at every level of fleet operation. This further extends battery life, while simultaneously informing smarter maintenance strategies and long-term capital planning.
Case Study: Successful Implementation of ZIVAN Recharge Rooms
Faced with a growing electric forklift fleet, one multinational distributor sought to eliminate inefficiencies related to uneven battery usage, unplanned downtime, and manual oversight.
In response, ZIVAN deployed its Brain System in conjunction with a Take-Me control unit, allowing for centralized fleet management across four Recharge Rooms from a single PC. The system supported a charging infrastructure consisting of:
- 64 NG3s
- 25 NG7s
- 16 NG9s
Each charger was assigned a unique ID and integrated into a network-wide battery monitoring framework. With what result? Predictable charge cycles, uniform wear across the fleet, and significant reductions in downtime and operator burden.
Following the system’s success, one of the distributor’s end users (an automotive OEM) expressed further interest, demonstrating the platform’s scalability and cross-sector relevance.
ZIVAN: Charging Future-Ready Fleets
In a fully electrified future, fleet performance is determined not simply by battery quality, but by the intelligence of the systems supporting it. ZIVAN’s Recharge Rooms bring this strategic edge to electrification today, elevating battery charging from necessity to operational advantage.
As a member of the ZAPI GROUP, ZIVAN delivers four decades of experience in battery charger solution development and integration—paired with an unmatched ecosystem of suppliers and technical experts. From initial consultation through ongoing support, ZIVAN provides the platform OEMs need to electrify with confidence, efficiency, and precision.
To learn more, watch the full webinar, or connect with a ZIVAN expert, Matthew Moore, to explore how Recharge Rooms can support your electrification strategy.
Matthew Moore e-mail: matthew.moore@zapiinc.com
Media Contact
Violetta Fulchiati | Marketing & Communication Specialist
Phone: +39 0522 960593
E-mail: marketing@zivan.it