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How Fonterra Turned 3-Month Batteries Into 3-Year Performers — And Why Battery Town Recommends VARTA for New Zealand Fleets
Fonterra operates one of the most demanding truck fleets in New Zealand. With more than 500 tankers collecting milk from nearly 9500 farms every day, these vehicles cover close to 100 million kilometres a year, much of it on rough rural roads where vibration, dust and constant electrical load punish every component on the truck.
Back in 2010, the weakest link in the entire fleet was something most people never see: the batteries.
When Truck Batteries Only Lasted Months
Fonterra’s tankers were burning through batteries in as little as three to six months. Constant replacements meant higher costs, unexpected breakdowns, and hundreds of failed batteries needing recycling every year. For a fleet operating on tight milking schedules, battery failures weren’t just inconvenient, they were operational risks.
Fonterra needed a commercial battery that could survive New Zealand’s rural environment, vibration, long hours and modern electrical systems.
The VARTA® ProMotive AGM Difference
Working with HCB Technologies and VARTA®, Fonterra trialled the VARTA ProMotive AGM (A1), a heavy-duty commercial battery designed for extreme vibration resistance and the high electrical demands of modern transport fleets.
The results were standout:
- One set removed after 280,000 km still tested at 95% of its original capacity.
- Another pair ran 31 months and nearly 800,000 km, a fleet record.
- Battery lifespan jumped from months to multiple years.
Today almost every Fonterra tanker runs on VARTA ProMotive AGM, proving the technology’s capability in the toughest operating conditions in the country.
Where Battery Town Fits In
Battery Town is New Zealand’s nationwide battery specialist network, and we supply and install the same VARTA ProMotive AGM batteries trusted by major commercial fleets.
But we don’t just replace batteries.
We diagnose the problems before they cost businesses time and money.
Battery Town technicians can:
- Fit VARTA commercial batteries correctly, including AGM-specific installation and charging requirements.
- Assess truck electrical systems for charging irregularities, parasitic drains, and wiring faults.
- est alternator output and monitor voltage stability under load.
- Identify early-stage failures long before they become roadside breakdowns.
- Recommend preventative upgrades, including vibration control and system setup checks for rural or high-duty fleets.
For fleet owners, this means longer life from every battery, fewer disruptions, and a more predictable maintenance cycle, the same advantages Fonterra now enjoys.
Engineering Solutions for New Zealand Roads
One of the reasons the VARTA solution worked so well for Fonterra is because the technology was paired with smart engineering:
- Anti-vibration mats designed to reduce shock loading
- On-truck data logging to monitor battery conditions
- Close technical collaboration to refine installation and charging setups
Battery Town workshops across New Zealand apply the same principles, matching the right battery to the right environment and ensuring it’s fitted for maximum life.
If your trucks operate on gravel roads, hilly terrain or long-distance cycles, Battery Town can tailor the setup to extend battery life dramatically.
Real-World Benefits for Fleets
Fonterra’s results speak for themselves:
- Battery usage dropped from 1400+ batteries a season to roughly 420 per year, even with a larger fleet.
- Trucks that once needed multiple replacements annually now run two to three years between changes.
- Downtime has reduced significantly.
- Waste has dropped, lowering environmental impact.
These are the same outcomes Battery Town aims to deliver to transport operators, contractors,
earthmovers, rural businesses and heavy commercial fleets across New Zealand.
Setting a New Standard for NZ Transport
The performance was so impressive that Fonterra’s experience helped influence Volvo to factory-fit VARTA ProMotive AGM batteries for New Zealand-bound trucks, a shift driven by real data, not marketing claims.
Battery Town is proud to supply the same AGM technology, backed by trained technicians who understand both the product and the electrical systems behind it.
If your fleet relies on uptime, reliability and controlled running costs, upgrading to VARTA ProMotive AGM through Battery Town is one of the most effective changes you can make.
Talk to Your Local Battery Town for a Fleet Assessment
Whether you run one truck or a nationwide operation, Battery Town can:
- Review your current battery and charging setup
- Test system health
- Identify issues before failures occur
- Recommend the correct VARTA commercial battery
- Install with AGM-specific expertise
- Provide ongoing electrical monitoring and support
Find your nearest Battery Town and book a commercial battery assessment today. Your fleet works hard — your batteries should too.