Innovative Off-Grid EV Charging Solutions for Costco Wholesale
Costco EV Charging
Introduction
Costco has emphasized the importance of implementing renewable energy solutions as part of its commitment to environmental sustainability and reducing its carbon footprint. With the increasing demand for electric vehicles and the necessity to support EV infrastructure, the Mira Loma Distribution Facility was chosen to host a pilot project to facilitate economically feasible, fast and effective charging infrastructure.
The Story of Costco Distribution
The Mira Loma pilot project stems directly from Costco’s Climate Action Plan supporting its corporate ESG initiatives and aligns with the three pillars of their Climate Action Plan:
1. Commitment to doing their part for the environment;
2. Contribution to real, results-driven positive impact and;
3. Continuous Learning & Improvement.
In pursuit of these objectives, Costco is introducing EVs to its vehicle fleet and, as a result, needs rapidly deployable charging infrastructure to power its EV fleet. The ~1M ft2 Mira Loma distribution center was selected as a pilot site to assess the technology available to achieve their objectives, understand project timelines and economics, and evaluate the interoperability of vendor solutions from the power electronics, storage and charging components to the structural requirements to house and support them.
The Challenge of Adding EV Infrastructure
The rapid adoption of EVs poses unique challenges, particularly regarding:
- Utility Service Capacity Limitations: Existing electrical service infrastructures struggle to support the dramatic increase in power EV charging stations present.
- Infrastructure Development Delays: Upgrades and retro fitment of existing electrical services, improvements and upgrades often take extended periods to plan, permit and implement.
- Need for Sustainable Solutions: For true environmental impact, increasing the reliance on 100% renewable energy sources to power EVs is imperative.
Why Costco Chose Sol-Ark
To bypass the protracted timelines of traditional electric infrastructure development, grid & service capacity limitations, and delays in grid-tied infrastructure permitting, the four integrated EV charging structures generate energy and produce power while operating completely off-grid.
The solar modules mounted on the Trinity Structures canopy harvest energy, which is regulated by the Sol-Ark 60KW to either store the energy in the EndurEnergy ESS (batteries) or convert to usable 480VAC, providing the power to run the Orange EV Charger or provide a backup power source in the event utility power is lost in the main facility.
The 60KW C&I hybrid inverter from Sol-Ark is uniquely suited to this project’s requirements. Sol-Ark has been providing highly reliable, high-capable grid-forming power electronics for off-gridapplications since its inception over 10 years ago. The integrated DC-DC converter with four independent MPPT channels allow for the most efficient energy conversion and a 96.5% efficiency rating without the need for additional conversion devices. The native 480VAC output, NEMA3R outdoor rating, wall-mounted form factor with integrated AC and DC cable landing box enables rapid and flexible integration to outdoor structures.
How Sol-Ark Responded (The Solution)
In collaboration with our partners, Trinity Structures and EndurEnergy, we were able to provide four integrated, stand-alone structures, each with the following:
1 x Sol-Ark 60KW 480VAC, with 4-Channel MPPT
1 x Trinity Structures Solar Parking Canopy (14’ parking)
2 x EndurEnergy ESP-R12 HV 61.44KWH ESS racks (120KWH/structure)
1 x 22KW 227/480VAC Orange EV Charge Station (pad mounted)
42 x 450W Modules (19KW DC-Coupled Solar)
Each installed system supports a 22kW DC fast charger by generating almost 100kWh per day from the solar array. The excess stored energy enables round-the-clock charging for their EV fleet.
The Results
Costco committed to converting depot yard trucks from diesel to alternative fuel models by 2035.
Their electrified structures are projected to create over 100 megawatts of solar energy annually,m providing 11,750 hours of off-grid fleet vehicle recharging and offsetting 3 million tons of carbon dioxide emissions. Due to California’s WAIRE program, Costco offset $9.8 million in state regulatory fees.
The pilot site proved to be a significant leap forward for fleet electrification. In only four months, accomplishing design, construction, and deployment with electrified structures that create,convert, and conduct solar energy. The infrastructure Costco has employed in the Mira Loma pilot facility can be added without the cost and time burdens of facility electrical upgrades, permitting, and civil works of traditional electrical infrastructure projects.
With Sol-Ark’s C&I hybrid inverters ability to provide off-grid power, Costco was able to scale their EV charging infrastructure quickly and cost effectively. They avoided hundreds of thousands of dollars on trenching and transformers, removing the need for new utility service. Additionally, they eliminated any kind of Time-of-Use and demand charges, and avoided the lengthy interconnection process typical of traditional electrical infrastructure.
By addressing the challenges associated with electric infrastructure development, grid limitations, and sustainability, Costco has established a benchmark for future projects. This initiative reflects a committed effort towards a greener future. It exemplifies how corporations can adapt and innovate in renewable energy and electric vehicle support.
