LONG BEACH, California—Armored vehicles likely are not high on anyone’s list of applications suited to lead the commercial fleet transition to electric vehicles. However, Will Ryder, vice president for fleet operations at Brinks, kept his options open.
The company wanted to explore alternative fuels for its fleet of 4,000 vehicles, both for environmental benefits as well as operational efficiencies, Ryder explained during an educational session here at the NAFA Institute & Expo 2025. After looking into propane and hydrogen, Brinks put out an RFP that led to an initial order of nine Ford E-Transit vans.
That cautious pilot program has grown into a rapidly expanding fleet-wide transformation, with plans to add another 30 electric vans and then 60. And the company's journey reveals a sophisticated approach to overcoming the unique challenges of electrifying armored vehicle operations.
“We collected the data over a two-year period,” Ryder said. “We looked at everything from the fuel savings to the repair and maintenance savings, labor savings, the savings for upfitting the vehicles, and then operationally, ergonomically.”
A multi-pronged approach
The initial barriers were significant. Armored vehicles, traditionally heavy and fuel-intensive, seemed an unlikely candidate for electrification. However, Brinks discovered that strategic modifications could make EVs not just feasible, but advantageous.
The company’s multi-pronged approach started with material innovations. Replacing steel armor with materials like Kevlar and Dyneema dramatically reduced vehicle weight, enabling electric vehicle integration.
Route optimization was also a critical component of the strategy. Brinks carefully analyzed their 144 U.S. and 35 Canadian branch locations, identifying routes that could be effectively served by electric vehicles.
The pilot program revealed substantial benefits beyond simple fuel savings, including improved operational efficiencies and reduced maintenance costs.
“Because an electric vehicle would not have been our first choice, it really changed the way that Brinks started looking at operations, as well,” Ryder said. “That’s where the pilot came into play. We started operating these vehicles alongside the conventional ICE vehicles—and the results were just phenomenal.”
Indeed, Brinks has seen significant improvements in operational efficiency, with drivers able to complete more stops and avoid time-consuming fuel station visits. Maintenance costs represent another substantial advantage. Electric vehicles require approximately 45-50% less maintenance compared to traditional internal combustion engine vehicles.
See also: What the Big Three automakers plan for fleets in 2025
Partnerships are critical
Ford Pro played a crucial role in the ongoing transition, providing not just vehicles but a comprehensive electrification ecosystem, including the sophisticated telematics essential to optimizing EV performance. David Fish, senior solution sales manager, Ford Pro Charging, emphasized the importance of education and infrastructure in successful fleet electrification.
"Most fleet operators don't understand what EVs are truly capable of," Fish said. "Our job is to help them understand how electric vehicles can integrate into their existing operations."
The financial implications are compelling. Fish noted that less maintenance means more uptime, another positive in the TCO equation. Ford Pro's data suggests that most fleets can transition approximately 60% of their vehicles to electric, with an average return on investment of just three years.
“When we start to connect the dots, it's not just one piece that we're looking at; it's several,” Fish said.
The Ford E-Transit vehicles Brinks is deploying come with a 100,000-mile powertrain warranty, potentially extending vehicle lifecycle and reducing long-term operational expenses.
“When we look at the reliability, especially with the armored upfit, it's like night and day between the EVs versus the ICE vehicles,” Ryder said.
Real-world operating reports on the benefits of commercial EVs will drive the transition, suggested Jonathan Harris, director, EV fleet solutions, with Revolv, a company whose mission is to support fleet electrification by handling vehicle acquisition, infrastructure, and maintenance.
“That's music to my ears,” Harris said, referring to the discussion of the positives for EV adoption. “For years, we were talking about those things as being benefits, but didn't have the data to back it up. So it's nice that we're now kind of along the path a little further, and we have some of that data to back up what we had as a promise.”
Brinks turned to Revolv to manage many elements of the transition, from setting up the lease payments to developing the charging infrastructure to getting the Brinks branding put on the vehicles.
The partnership between Brinks, Ford Pro, and Revolve exemplifies the collaborative approach needed for successful fleet electrification. By combining vehicle technology, charging infrastructure, financial services, and operational expertise, they're creating a comprehensive roadmap for other fleets considering electric transformation.
Changing the culture
Ryder emphasized that the transition isn't just about technology, but about changing organizational culture.
By implementing internal communication strategies like quarterly town halls and creating QR-coded information systems on vehicles, Brinks is ensuring driver engagement and understanding.
Charging infrastructure, often cited as the primary barrier to EV adoption, is being addressed through sophisticated load management solutions. Ford Pro's charging software can prioritize vehicle charging based on battery state, manage site-level electrical constraints, and even enable remote vehicle preconditioning.
Looking forward, Brinks plans to electrify nearly its entire fleet, with only shuttle trucks for heavy loads remaining as internal combustion vehicles. The company is actively exploring emerging battery technologies, particularly silicon-based lithium solutions that could further expand its electric capabilities
As industries worldwide seek to reduce carbon footprints and improve operational efficiency, Brinks' strategic approach offers a compelling case study.
Their journey demonstrates that with the right technology, partnerships, and organizational commitment, electrification is not just possible—it's potentially revolutionary.
“You want to push these EVs to the limit of what that vehicle can do,” Ryder said. “And it takes that data, aggregating that data, looking at that data—and it takes time to do that.”
