Charged EVs | Solving EVSE deployment and scalability challenges with flexible power distribution

How Starline’s Scalable Busway Systems Can Transform EV Charging Infrastructure

The rapid growth of electric vehicle adoption is putting immense pressure on charging infrastructure, with site constraints, installation costs, and scalability emerging as key challenges. As cities, businesses, and fleet operators work to expand EV charging networks, traditional power distribution methods are proving inefficient, costly, and difficult to scale.

Starline, a leader in power distribution solutions, is bringing its expertise in track busway systems to the EV charging sector. During a recent webinar hosted by Charged, Doug Moore, Senior Product Manager, and Adrian Sanchez, Director of Commercial & Industrial Sales at Starline, discussed how the company’s busway technology provides a more flexible, cost-effective, and scalable alternative to conventional hardwired installations.

The Growing Need for Scalable EV Charging Infrastructure

EV adoption is accelerating at an unprecedented pace. In the U.S. alone, public EV charging stations have surged from fewer than 500 in 2009 to over 60,000 today, with billions of dollars in federal funding fueling further expansion. Yet, despite these efforts, charging infrastructure remains a limiting factor for many drivers, particularly in urban areas where retrofitting existing buildings is often complex and expensive.

“We’re seeing an enormous shift toward electrification, especially in commercial fleets,” said Sanchez. “Businesses need charging solutions that are not just functional today but adaptable for future growth.”

This need for scalability is where Starline’s busway systems stand out. Initially designed for data centers and industrial facilities, the technology is now being deployed for EV charging projects, addressing many of the pain points that have hindered large-scale deployment.

Challenges in EV Charging Deployment: What’s Holding Us Back?

A live poll during the webinar highlighted the primary challenges faced by EVSE (Electric Vehicle Supply Equipment) installers:

• Site readiness and infrastructure costs (45%)
• Overall installation costs (40%)
• Planning for scalability and future growth (30%)
• Electrical labor resource availability (10%)

These findings align with industry observations: trenching, conduit installation, and panel upgrades significantly drive up costs and complexity. Retrofitting older buildings or multi-level parking structures further complicates matters.

“We constantly hear from customers struggling with the limitations of traditional wiring methods,” said Moore. “If you need to add more chargers a few years down the line, hardwired solutions require extensive rework, increasing costs and downtime.”

How Starline’s Busway System Provides a Flexible Alternative

Starline’s busway systems offer a modular, overhead power distribution solution that eliminates the need for extensive trenching or conduit runs. Instead of relying on fixed circuits, the system provides continuous access to power through an open-channel track, allowing chargers to be easily added or repositioned.

Key Benefits of Starline Busway Systems for EV Charging:

• Scalability: Power distribution can be extended or modified without major infrastructure changes.
• Cost Savings: Eliminates costly trenching and conduit installation, reducing overall project expenses.
• Speed of Deployment: Installations are significantly faster, often completed in a fraction of the time required for traditional wiring.
• Flexibility: Chargers can be installed, relocated, or upgraded as needed without requiring major electrical work.
• Safety & Reliability: Enclosed conductor bars prevent exposure to live components, while the system meets IP54 standards for protection against dust and moisture.

“Our busway system acts like an overhead power grid,” Sanchez explained. “It brings power where you need it, allowing for easy plug-and-play installation of charging equipment.”

Real-World Application:  JE Dunn Headquarters Case Study

One of the most compelling demonstrations of Starline’s solution in action is its recent installation at JE Dunn Construction’s headquarters in Kansas City. Faced with the challenge of adding EV charging to a decades-old parking garage, the company needed a solution that minimized disruptions and future-proofed the site for expansion.

Project Highlights:

• Initial Setup: Installed two Level 2 wall-mounted chargers powered by Starline’s Series S Track Busway system.
• Retrofitting Constraints: No space for traditional conduits, and power shutdowns needed to be minimized.
• Scalability & Expansion: Within weeks of installation, the company seamlessly expanded to support four chargers.

“The ability to scale up without tearing up concrete or running new conduit was a game-changer,” Moore noted. “And because the system is modular, adding more chargers is as simple as installing additional plug-in units.”

Beyond Passenger EVs: Expanding to Commercial Fleets and Logistics Hubs

Starline’s technology isn’t just for passenger vehicle charging—it’s already being used in diverse applications, including:

• Fleet Charging: Commercial operators are rapidly transitioning to electric vehicles, requiring scalable infrastructure that supports long-term growth.
• Warehouse & Logistics Centers: High-density charging solutions for electric forklifts and automated guided vehicles (AGVs) improve efficiency in distribution centers.
• Public Transportation: School districts and municipalities are electrifying bus fleets, necessitating reliable, space-efficient charging solutions.

At a large distribution center in Canada, Starline’s busway system streamlined power delivery for an electric forklift battery exchange station, reducing installation time and cost while improving operational efficiency.

“We’ve seen companies like Publix and Ikea adopt this approach for their warehouse operations,” Sanchez said. “It’s a perfect fit for facilities where flexibility and uptime are critical.”

The Future of EV Charging Infrastructure

As the EV market evolves, so too must its infrastructure. Key trends shaping the future of power distribution include:

• Higher-Powered Charging Solutions: Supporting next-generation ultra-fast chargers for commercial applications.
• Integration with Renewable Energy & Storage: Optimizing load management and leveraging off-peak energy.
• Advanced Power Monitoring: Enhancing grid responsiveness through real-time data analytics.

“Starline is committed to staying ahead of the curve,” Sanchez emphasized. “We’re continuously innovating, expanding our manufacturing capabilities, and collaborating with industry leaders to develop smarter, more adaptable power solutions.”

For businesses and municipalities seeking scalable, cost-effective EV charging infrastructure, Starline’s busway systems offer a compelling alternative to traditional hardwired approaches. With a track record of success in demanding industrial environments, the company is well-positioned to help drive the next phase of EV adoption.

A Smarter Approach to EV Infrastructure Deployment

With EV adoption accelerating worldwide, outdated power distribution methods can no longer keep pace with demand. Starline’s track busway technology presents a scalable, flexible, and cost-efficient alternative, eliminating many of the bottlenecks associated with traditional wiring.

As businesses and governments expand charging networks, the ability to quickly deploy, modify, and scale infrastructure will be crucial. By leveraging modular busway systems, the industry can future-proof installations while significantly reducing costs and installation time.

For more information on Starline’s solutions, visit Starline Power or check out the Charged webinar here.