EMO Energy, a battery systems company focused on high-utilization electric fleets, has released findings from four years of real-world operational data covering 10 million kilometers across commercial delivery fleets in Bangalore and Gurgaon. The data, drawn from 100 battery packs monitored through the company's proprietary platform SENS, shows that batteries operating under frequent fast-charging conditions degraded by approximately 15% after 75,000 kilometers — a figure the company says is materially lower than what is typically observed in conventional EV packs under similar usage.

The battery packs in the dataset power delivery vehicles running quick-commerce routes, covering close to 100 kilometers a day. Vehicles undergo four to five fast-charging sessions daily, each roughly five minutes long, totaling about 20 minutes of charging time per day. Each battery pack has a capacity of 2 kWh, with a charging rate of 3.3 kW and a 0–80% charge time of around 20 minutes.

The operating environment is demanding. Vehicles run through Indian summers, monsoons, and winters. In Delhi summer conditions, ambient temperatures can exceed 45°C, which increases thermal stress during charging and discharge.

EMO's reported State of Health numbers across the dataset show the following trajectory: packs sit at approximately 96–98% after 20,000 km, 90–92% after 50,000 km, and 85–88% after 75,000 km. The company states that under conventional EV packs subjected to frequent fast charging, degradation of 25–30% by 75,000 km is not uncommon, with State of Health often falling into the 70–75% range. EMO also reports zero cases of thermal runaway across the dataset.

Thermal Architecture

EMO attributes part of the outcome to its thermal management design. The company uses a patented immersion cooling system in which cells are surrounded by a proprietary dielectric coolant circulating through the pack. The company reports that this keeps cell temperatures between 24°C and 28°C during fast charging, reducing the electrochemical stress that typically accelerates degradation.

The SENS Platform

Beyond hardware design, EMO points to its SENS platform as a key factor. Traditional battery management systems monitor voltage, temperature, and current, and intervene when a threshold is crossed. SENS, by contrast, continuously analyses telemetry from charging sessions, temperature profiles, cycle history, and usage patterns to model how individual batteries are aging. The platform produces degradation trajectory forecasts, detects early signals of abnormal behaviour, and adjusts charging profiles before long-term wear accelerates.

For fleet operators managing large vehicle counts, the platform is intended to reduce downtime and improve asset life planning.

The findings come as quick-commerce companies face increasing pressure to electrify last-mile delivery fleets. These operators typically run vehicles 80–120 km daily with multiple charging cycles and low tolerance for downtime. Two concerns — degradation under frequent fast charging, and uncertainty around long-term battery health — have been cited as factors slowing large-scale EV fleet adoption.

EMO's data suggests both concerns can be addressed through purpose-built battery design and predictive software, shifting the question for operators from whether EV batteries can sustain heavy use to how quickly fleets can scale.