The transportation industry is experiencing a radical change aimed at improving heavy commercial vehicle emissions and fuel economy. Innovations in cutting-edge technology, lubricants and cleaner fuels are driving this change. It is essential for fleet operators and transport engineers to understand these developments in order to optimise operations and comply with environmental regulations.
ALTERNATIVE FUELS
With commercial vehicle operators under more pressure than ever, they are faced with the day-to-day task of maximising profits while ensuring they comply with current and future emission regulations. As a result, many operators are now looking at the pros and cons of the fuels they use to power their vehicles to help reduce costs while meeting emission requirements.
“Moving forward, alternative fuels to traditional diesel are expected to be a growing part of the commercial vehicle energy mix,” explains Lauren Kreno, EU fuel products technical advisor, Esso. “While numerous alternatives have been, or are in the process of being developed, the leading contenders likely to have a significant impact are biofuels, liquefied natural gas (LNG), compressed natural gas (CNG) and electricity.”
Before switching to alternative fuels, Kreno says that operators need to consider factors such as vehicle cost, fuel availability, total distance, typical routes and average mileage to work out a total cost of ownership analysis to determine the best fuel and vehicle mix for their fleet.
“While trials and the use of alternative fuels are widely reported, diesel will continue to be a significant part of the fuels mix for large commercial vehicles, now and into the future,” Kreno says. “It’s important for commercial vehicle operators to choose reputable fuel suppliers who they can work with to develop the optimum fuels solution for their business.”
QUALITY IS KEY
Allison Transmission recently introduced TES 668, a high-performance transmission fluid claimed to offer enhanced oxidative stability, anti-wear performance and friction modifier durability compared to its predecessor, TES 295. The fluid improves shift quality and reduces noise, vibration and harshness even as it ages. Specifically designed for extended service intervals, TES 668 is ideal for vehicles that operate under heavy loads.
“In today’s world, where focus is placed upon rational cost savings, the use of a top-quality fluid can sometimes be overlooked,” states Nathan Wilson, account and area sales manager UK and Republic of Ireland, Allison Transmission.
“There are a range of problems that may arise from using an unapproved fluid in an Allison product, such as seal and friction issues, which will impact overall product durability. Using genuine automatic transmission fluid from an Allison approved or authorised partner is key to optimum performance and the durability of Allison’s products.”
Allison Transmission’s expertise has helped Biffa, a waste management company, save £200,000 annually on truck transmission servicing. By reviewing Biffa’s predictive maintenance schedules, Allison identified opportunities to extend service intervals without compromising performance or durability.
Previously, Biffa serviced its Dennis Eagle refuse trucks every 12 months, 600 hours, or 15,000 kilometres. Now, using Allison-approved TES 668/295 lubricants, intervals are extended to 36 months, 3,000 hours, or 120,000 kilometres.
These changes significantly reduce costs, saving Biffa 3,600 hours in labour and vehicle downtime annually. Additionally, oil consumption and disposal have been cut by 33,500 litres per year, aligning with Biffa’s ’Resourceful, Responsible’ 10-year sustainability strategy.
SIMPLE AND EFFECTIVE
FuelActive’s Fuel Pick-Up Unit enhances fuel efficiency and reduces emissions by replacing traditional fixed fuel pickups in the bottom of the tank with a floating one, drawing fuel from the top of the tank.
“The way in which we draw fuel from a tank has never been overhauled, it’s always been from the lowest permissible point,” explains Niall Carroll, sector sales manager for FuelActive.
“The challenge with that is that contamination, like water from condensation, is heavier than the diesel and sinks to the bottom and gets ingested, which is where problems like degraded engine performance and lifespan begin.”
Carroll adds that the Fuel Pick Up Unit is proven in various sectors including mining, rail and road transport, and offers 5% fuel economy and CO2 savings (which may not sound like much, but will add up straight away compared to the amount needed to fit out a site with electricity/hydrogen fuel infrastructure) and delivers cleaner diesel to the engine. It is also proven with greener fuels such as hydrogenated vegetable oil, which is a lower carbon alternative fuel.
“The beauty about FuelActive is that it’s as simple as it is effective – it’s an entirely analogue device which means there’s no service requirements,” Carroll says.
“The best time to fit FuelActive is in a new vehicle. We cannot reverse wear, so the impact is less on older vehicles because the damage has already been done. But, if we can maximise the performance and the longevity of your critical components, such as injectors, we know that you will always get the best possible combustion, therefore you will have cleaner emissions.”
NEW STANDARDS
Fuels and lubricants are designed to a specific set of standards (specifications, performance parameters, etc) which have been identified and defined in conjunction with equipment manufacturers and industry bodies. They are, in effect, like any other engineering component of a vehicle. As such, they must be verified.
Verification of Lubricant Specifications (VLS) is an independent organisation providing a credible and trusted means to verify lubricant specifications. It aims to bring transparency to the marketplace by investigating and resolving lubricant product complaints concerning incorrect performance claims, misleading technical specifications, and products that do not met OEM or stated industry standards.
Alan Outhwaite, chairman, VLS Technical Review Panel, says: “Industry standards and OEM specifications cover the physical aspects, like viscosity, the chemical aspects, such as the particular levels of certain elements in lubricant formulations, as well as demonstrated performance in specific engine tests.”
In October 2024 a new standard for heavy-duty engine oils was introduced due to an increased shift to lower viscosity oils. Known as ACEA F01-24, the new category is specifically designed for low viscosity oils that have high temperature, high sheer characteristics which work to improve fuel economy.
Outhwaite says that the increasing use of biomatter in conventional fuels, such as B7 Diesel containing 7% fatty-acid methyl esters (or FAME) designed to reduce lifecycle CO2 emissions and improve fuel lubricity, pose a significant challenge for lubrication formulators.
“Modern engine oil formulations must pass stringent biodiesel compatibility tests,” he adds. “There is the potential to produce high performing bio-based base oils for lubricant applications, which in part utilise some conventional refining technologies.
“However, the challenge with the increased use of biomatter is the scalability of the small renewable base oil refiners which is currently modest and requires a huge amount of investment.”
CLEANING UP
Something that Outhwaite says will become more prevalent in the coming years, due to the pressure being put on companies to provide a circular economy, is oil recycling.
“There are some fairly aggressive recycling processes that are cleaning up used engine oil in a way that has not been seen before,” says Outhwaite. “They can potentially produce high-performance base oils that can be used as part of formulations going forward without compromising the specification.”
It is critical for fleet operators and transport engineers to remain up to date on developments aimed at improving heavy commercial vehicle emissions and fuel economy.
Incorporating cleaner fuels, sophisticated lubricants and innovative technology not only guarantees adherence to changing requirements but also improves sustainability and operating efficiency. The transport industry can make a substantial contribution to a cleaner and more sustainable future by adopting these innovations.
