The drivers in order of impact
In our experience, the largest avoidable costs come from time spent at collection sites: waiting for access, loading packs that are not palletised, or resolving missing paperwork. Distance matters, but a well-planned route over a longer distance can cost less per pack than a series of short, poorly prepared trips.
The ranking below reflects typical patterns across our network. Individual sites vary, but the same themes appear repeatedly when we analyse why some collections cost far more than others.
| Rank | Driver | How to reduce it |
|---|---|---|
| 1 | Site dwell and loading time | Palletise packs and confirm access in advance |
| 2 | Load consolidation | Batch retirements into scheduled pickups |
| 3 | Documentation readiness | Complete manifests and declarations before booking |
| 4 | Condition of batteries | Declare damage early so packaging is correct |
| 5 | Distance travelled | Use the nearest suitable facility |
Consolidation in practice
A single collection of many packs spreads vehicle, crew and documentation cost across all of them. Fleets that retire vehicles steadily can agree a regular collection schedule, while smaller holders can use shared milk runs that visit several sites in one trip.
Consolidation also improves safety, because packs spend less time in temporary storage. It is one reason we encourage holders to plan retirements rather than calling for collection one battery at a time.
- Agree regular collection days for steady volumes
- Join shared routes for small or occasional volumes
- Hold packs safely until a viable load is ready
Avoiding failed collections
A failed collection, where the vehicle arrives but cannot load, doubles cost and delays everything that follows. Common causes are missing declarations, packs at high state of charge, lack of loading equipment, or damaged packs that were not declared.
A short pre-collection checklist prevents most failures. Confirm documents, discharge levels, packaging, access times and loading equipment before the booking is confirmed.
Field note