We installed 6 dual Rolec chargers at Zeus Packaging in Biggleswade, expanding the site to 24 charging sockets across 12 pedestals. The project included collapsed ducting repair, full site load management, and a management platform with RFID access for staff. We secured £10,200 in Workplace Charging Scheme grant funding.
Zeus Packaging is a major packaging and food service supplier operating from a large warehouse and distribution centre at Stratton Business Park in Biggleswade, Bedfordshire. Here is a snapshot of what we delivered.
| Property Type | Commercial Warehouse and Distribution Centre |
| Location | Biggleswade, Bedfordshire |
| Completion Date | July 2023 |
| Project Duration | 1 Week |
| Chargers Installed | 6 x Rolec 22kW Dual Pedestal (12 New Sockets) |
| Total Sockets on Site | 24 (12 Existing + 12 New) |
| Load Management | Dynamic Load Balancing Across 24 Sockets |
| Access Control | RFID Card (Staff Only) |
| Funding Secured | £10,200 (Workplace Charging Scheme) |
| Client | Zeus Packaging Ltd |
Zeus Packaging approached us about expanding the EV charging at their Biggleswade warehouse and distribution centre. The company had started offering electric vehicles to staff through the Benefit in Kind scheme, and uptake had been faster than expected. Around 20 to 25 employees were already driving EVs, and the 12 existing charging sockets installed during the original warehouse build were no longer enough. The site needed more charging capacity, but the infrastructure had issues. Underground ducting in the car park had collapsed, the electrical supply was already under pressure from the original chargers, and the warehouse had to remain fully operational throughout any installation works. Zeus also wanted a single management platform to track charging across the entire site, covering both the existing and new chargers.
The existing underground ducting in the car park had collapsed. This meant new cables could not be routed to the charger positions until the ducting was fully replaced. Twelve metres of tarmac needed to be excavated and new ducting installed before any charger work could begin. Utility scans were conducted first to identify other underground services and avoid causing further damage during excavation. The car park remained in use throughout, with staff vehicles and delivery trucks moving around the site daily. The ducting repair had to be completed and the tarmac reinstated before any of the new chargers could go in.
Zeus Packaging already had 12 charging sockets installed during the original warehouse build. The additional 6 dual chargers would bring the total to 24 sockets, all connected to the same electrical supply. With 20 to 25 staff EVs on site at any given time, most of them charging during the working day, the electrical demand was significant. The new chargers needed to integrate with the existing infrastructure without overloading the supply. The existing distribution board had to serve both the original and new chargers, and the load had to be balanced dynamically so that all vehicles could charge without tripping the supply. Getting this wrong would not just affect the chargers. It could impact the warehouse operations.
Zeus Packaging is an active distribution site. Delivery vehicles arrive and depart throughout the day, staff need access to the car park at all times, and the warehouse operates on tight schedules. Any disruption to vehicle access or power supply would affect the business directly. The installation involved groundworks in the car park, cable routing through the warehouse roof space, and electrical work at the main distribution board. All of this had to happen while the site continued to operate normally. The work inside the building was carried out at height in the roof containment system above the warehouse floor, adding another layer of complexity to the programme.
Client testimonial pending.
We excavated 12 metres of tarmac in the car park to access and replace the collapsed ducting. New ducting was installed to route the cables from the external wall to each of the six charger positions. The intact section of ducting near the building was reused to connect through to the main electrical room, reducing the amount of excavation needed. Once the new ducting was in place, we backfilled the trench and reinstated the tarmac to match the existing surface. The car park was returned to full use with no visible sign of the repair work. The new ducting provides a clean cable route with capacity for future expansion if Zeus needs additional chargers.
We installed a load management system across all 24 sockets, covering both the existing and new chargers. This balances the electrical demand dynamically so that all vehicles can charge during the working day without exceeding the supply capacity. The system adjusts power distribution automatically based on how many vehicles are connected at any given time. We connected the new chargers to the existing distribution board and installed dedicated protection devices on each circuit. Separate data cabling was run for the management platform communications, allowing real time monitoring and control. The entire network now operates as a single managed system rather than two separate installations.
We brought all 24 sockets onto a single management platform with RFID card access for staff. Zeus management can see exactly who is charging, when, and how much energy each vehicle uses. This gives the business full visibility without creating admin burden for employees. Each member of staff received an RFID card linked to their profile on the platform. The platform provides usage reports, energy consumption data, and charger status in real time. Zeus can track charging patterns, identify any issues, and plan for future expansion based on actual demand data.
Zeus Packaging now has 24 charging sockets across 12 dual pedestal chargers, all managed through a single platform. Staff access charging via RFID cards. The management platform gives Zeus full visibility over usage, including who is charging, how much energy each vehicle draws, and when the chargers are busiest. The 20 to 25 EVs on site can all charge during the working day without overloading the electrical supply.
The £10,200 Workplace Charging Scheme grant covered a significant portion of the infrastructure and charger costs. The full installation was completed in one week, including the ducting repair, cable routing, charger installation, and platform configuration. The project was delivered without any disruption to the warehouse operations or delivery schedules.
The load management system means Zeus can add more chargers in the future as staff EV adoption continues to grow. The ducting is repaired and the cable containment has spare capacity for additional circuits. With Benefit in Kind driving more staff toward electric vehicles, the infrastructure is already in daily use and ready for the next phase of expansion. Zeus has a charging network that runs itself, with no billing admin, no access issues, and full reporting on demand.
Every project surveyed, installed, commissioned and monitored by our own team. Grants secured and managed end to end.
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