Stackable Charging Solutions: Foundational for Future-Ready Fleets

How do you measure the value of operational versatility? 

While it may not be easily quantifiable, versatility drives greater ROI across the value chain, determining how efficiently industrial machinery scales to the growing electrification imperative.

Choice of charging infrastructure remains a critical enabler of—or bottleneck to—operational versatility. Monolithic off-board chargers often deliver fixed output, require dedicated space, and all at a high infrastructural investment.

Stackable charging solutions, in contrast, enable agile and versatile operations. By delivering just the right amount of power to suit the application, machine, and duty cycle, OEMs enable scalable and streamlined charging logistics.

How do stackable charging solutions work? And how can OEMs and fleet managers deploy them to maximum effectiveness? 

What is Stackability? Addressing Logistical Charging Challenges

The idea of “industrial charging” often carries certain connotations: rows of heavy-duty off-board chargers tethered to designated charging bays.

While this image may be accurate in some applications with mature electrification strategies (such as material handling), the reality is often more nuanced. 

For many manufacturers, especially those with diverse fleets or electrification projects still underway, the infrastructure and cost demands of centralized charging prove far too limiting. 

Instead, an increasing number of OEMs opt for “stackable” charging solutions, defined by: 

• Multiple, low-output chargers (e.g., 3–7 kW) versus large, singular ones
• Stackable profiles, enabling these chargers to operate in parallel for scalable power
• Availability in on-board and off-board varieties to meet OEM needs

These modular setups provide just the right amount of power to charge machinery in line with applicable duty cycles. Unlike singular charge bays sized to the fleet’s maximum charging needs (resulting in excess energy draw), stackable systems deliver targeted power as needed to the application.

Operational Advantages of Stackable Charging

Stackable chargers solve many everyday constraints OEMs face as they undergo electrification. These tangible advantages manifest across five key areas: 

1. Versatile configuration - Deployable as either on-board solutions for simplified AC outlet charging or as dedicated off-board solutions with a smaller footprint, stackable chargers effortlessly meet OEM charging requirements rather than requiring intensive infrastructural reworks.
2. Diverse machine support – Multiple chargers support different voltages and battery chemistries simultaneously, eliminating the complexity of multi-voltage systems or hardware swaps. Stackability offers a clear path to electrifying even mixed fleets.
3. Built-in redundancy – Centralized, high-power chargers introduce a greater risk of operational bottlenecks should they fail. Stackable configurations, in contrast, ensure continuous operation in mission-critical applications where downtime means lost income.
4. Scalable to power demand – Stackable chargers allow for incremental power increases to suit the application. For example, a charger that individually delivers 3.3 kW of power may scale up to nearly 20 kW when stacked to a total of six units, meeting fine-tuned charging schedules and top-ups as needed.
5. Smart cost control – Besides freeing up room for revenue-generating activities, stackable charging solutions ensure machine uptime, optimize charging times, and eliminate the wasted capacity typical of centralized solutions. All of this contributes incrementally to better ROI. 

Stackable setups thus support OEMs with the flexibility to adapt and expand without overcommitting. With a lower overall initial investment and modular scalability, they offer a practical path for phased growth as more machines go electric across the fleet. 

Real-World OEM Applications for Stackable Charging

Versatility may be challenging to quantify, yet its value becomes apparent when examined in the context of common OEM verticals.

Below are several high-impact use cases where stackable systems deliver measurable strategic advantages: 

• Material handling – Electrified forklifts depend on reliable, round-the-clock operation. Stackable chargers ensure uninterrupted availability through built-in redundancy, allowing operations to continue even during maintenance or component failure. On-board or off-board, chargers can be configured for lead-acid, AGM, LFP, or any other chemistry—all within the same charging zone.

• Aerial work platforms (AWPs) – Scissor lifts and telescopic booms demand intermittent usage patterns, and often in areas with limited access to dedicated electrical infrastructure. The right stackable charger equips AWPs to charge quickly and efficiently from basic residential outlets or even public EV charging stations, greatly expanding operational versatility.

• Construction fleets – As demand rises for warehousing, logistics hubs, and data centers, electrified rental equipment is seeing broader deployment. Stackable solutions offer a versatile, customer-friendly alternative to bulky fixed infrastructure—allowing rental providers to support growing inventory without committing to stagnant installations.

These use cases extend well beyond the listed verticals and scenarios. The right charging solution can service electrified machinery in applications including:

• Agriculture
• E-mobility
• Floor care
• AGVs and AMRs
• Turf equipment 
• Maritime

In every case, the ability to scale charging infrastructure to the machine, the site, and the duty cycle presents stackable charging as an attractive choice to future-proof electrification strategies.

ZIVAN’s CT3.3: The Ideal Stackable Charging Solution 

For OEMs seeking to maximize versatility, ZIVAN’s next-generation CT3.3 charging solution offers the ideal platform. Delivering 3.3 kW of output power per unit, the CT3.3 is stackable up to 19.8 kW, meeting charging needs across light- to mid-power industrial applications. 

This charging solution offers:

• Universal AC input compatibility (85–270 V AC) for global deployment 
• Compact, ruggedized design with IP67-rated protection ideal for harsh outdoor worksites
• Full compliance with international safety and EMC standards for accelerated time-to-market
  
  

Further adding to its operational versatility, the CT3.3 is configurable with a suite of optional integration features, including:

• Electric vehicle supply equipment (EVSE) interface for compatibility with public EV chargers
• Integrated 500 W DC-DC converter to power auxiliary loads, such as lights and climate controls 
• Input over-voltage protection (OVP) circuit for charging reliability in unstable grid environments 

The CT3.3’s automotive-grade design and flexibility to deploy as either an on-board or off-board charger equips OEMs with the versatility needed to optimize operational ROI.

ZIVAN: Powering the Future of Versatile OEM Operations 

Operational versatility may be difficult to quantify—but its impact is undeniable. 

From fewer infrastructure constraints to faster deployment and smarter energy use, the right charging architecture can transform how equipment is deployed, managed, and scaled.

With stackable charging solutions, OEMs no longer need to compromise between performance and versatility. Whether charging equipment on-site, in the field, or through public infrastructure, ZIVAN’s CT3.3 delivers the agility to maximize ROI. 

Ready to start building your future-ready fleet? 

Contact a ZIVAN expert to see how the CT3.3 can power your next electrification project.

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