Fuel efficiency in heavy-duty trucks - strategies and driving techniques

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April 22, 2025
  • Fuel efficiency
  • Heavy Duty

Rising fuel costs and stricter environmental regulations are creating big challenges for global transportation. However, with the right approach, these challenges can be successfully managed.

This article explores practical methods to improve fuel efficiency in heavy-duty trucks. From enhancing driving techniques to leveraging the latest technological advancements, we provide comprehensive solutions that can be implemented immediately.

These measures help transport companies cut costs and reduce environmental impact.

Fuel efficiency in heavy-duty trucks (10 tons and above) 

Fuel efficiency is a critical factor in the operational cost and environmental impact of logistics operations worldwide. For heavy-duty trucks with a gross vehicle weight of 10 tons or more, the average fuel consumption is approximately 3 to 5 kilometers per liter.

This figure is about one-fifth of that of a standard passenger car, making it a key cost determinant for transport businesses. An important thing to remember is that fuel efficiency can change a lot depending on driving conditions.

For example, the difference in fuel consumption between a fully loaded and an empty truck can be as much as 25%. Since multiple factors influence fuel efficiency, tracking and optimizing fuel consumption has become an important focus for logistics companies worldwide. 

Factors impacting heavy-duty truck fuel efficiency 

Fuel efficiency in heavy-duty trucks is affected by a mix of vehicle design, operational methods, and external conditions. By recognizing these factors and managing them well, it is possible to save a lot of fuel. 

Impact of vehicle weight 

A major challenge for heavy-duty trucks worldwide is how vehicle weight affects fuel efficiency. Even when empty, trucks weighing 10 tons or more are still several tons heavy, and adding cargo further increases fuel consumption.

One important factor is the link between load size and fuel efficiency. For example, a truck that gets 5 km per liter when empty might see its fuel efficiency drop to 3.5 km per liter when fully loaded.

Fuel consumption of large-displacement engines 

Heavy-duty trucks have large engines of 10 liters or more, built to provide strong power for carrying heavy loads. However, this high performance also leads to higher fuel consumption, which is a common challenge for transport companies around the world.

These engines use a lot of fuel, even when idling or driving at low speeds, because they need to generate enough power to move heavy cargo. This is especially noticeable in older trucks, which are less fuel-efficient compared to newer models with advanced technology. To address this, improving engine performance and efficiency has become a major focus globally, helping to lower fuel consumption and support a more sustainable logistics industry. 

Aerodynamic and running resistance

The shape and design of a truck play a big role in air resistance and rolling resistance, both of which affect fuel use. Truck makers around the world focus on this to improve efficiency.

Air resistance increases as speed goes up, meaning fuel consumption rises much faster at higher speeds. Also, when a truck is heavier, its tires press harder against the road, creating more rolling resistance. This makes fuel efficiency drop, especially when driving on highways. 

Driver behavior and operational habits

A driver’s driving techniques and habits directly influence fuel consumption. The global transport industry is paying more attention to how driver habits affect fuel efficiency and finding ways to improve it.

Rapid acceleration and sudden braking require maximum engine output, which significantly increases fuel consumption. Similarly, frequent low-gear driving and stop-and-go movement negatively affect fuel economy. Enhancing efficient driving skills is an important priority for logistics companies worldwide. 

Lack of regular maintenance

Inadequate vehicle maintenance is one of the primary causes of fuel inefficiency faced by trucking companies globally.

A 30% reduction in tire pressure can lower fuel efficiency by 4.6%, while a 60% reduction may cause a decline of up to 12.3%. Ensuring proper tire inflation is crucial not only for fuel savings but also for environmental sustainability.

Additionally, clogged air filters can restrict airflow to the engine, reducing combustion efficiency, while degraded engine oil increases internal friction, leading to higher fuel consumption. These issues can be prevented through routine maintenance. 

Excessive idling and its impact

Excessive idling is a major factor in unnecessary fuel consumption in the transport industry. It is estimated that a heavy-duty truck idling for one hour consumes approximately 1.5 liters of fuel.

Furthermore, when the air conditioning is running, fuel consumption increases even more. To address this issue, idle-stop technology adoption and driver awareness programs are being promoted worldwide.

Monitoring and managing idling time are crucial in reducing fuel wastage. 

 

Strategies to improve fuel efficiency in heavy-duty trucks 

Enhancing fuel efficiency has become a key priority for the logistics industry worldwide, offering both economic and environmental benefits. Below are effective strategies to optimize fuel consumption. 

Enhancing driving techniques

Practicing eco-driving is one of the most effective approaches to improving fuel efficiency. Avoiding sudden acceleration and abrupt starts while maintaining an engine speed between 1,500 and 2,000 rpm can lead to significant fuel savings.

For example, utilizing cruise control on highways to maintain a steady speed helps reduce unnecessary fuel consumption. Additionally, reducing idling time can save approximately 1.5 liters of fuel per hour, making it a practical and immediate way to enhance fuel efficiency. 

Implementing regular vehicle maintenance

Routine vehicle maintenance plays a crucial role in maximizing fuel efficiency. Key areas of focus include tire pressure control, air filter cleaning and replacement, and regular engine oil changes.

Proper tire pressure control is particularly important. Keeping tires inflated to the recommended pressure minimizes running resistance and improves fuel economy. Furthermore, changing engine oil every 5,000 to 10,000 km helps reduce internal friction and optimize combustion efficiency. 

Optimizing cargo loading methods

Cargo loading practices have a direct impact on fuel efficiency. The key is to ensure optimal load distribution and balanced placement of freight.

Avoiding overloading and evenly distributing cargo across the truck enhances fuel efficiency. Additionally, reducing unnecessary cargo or equipment helps lower the overall vehicle weight, improving both fuel economy and operational safety. 

Planning routes for maximum efficiency

Strategic route planning can help minimize fuel consumption. Utilizing GPS navigation and real-time traffic data allows for the selection of routes with less congestion and fewer steep inclines.

Additionally, scheduling deliveries during off-peak hours, such as early morning or late at night, ensures smoother traffic conditions, leading to reduced fuel consumption and improved delivery efficiency. 

Upgrading to fuel-efficient vehicles

Modern heavy-duty trucks are equipped with advanced fuel-saving technologies. Innovations including lightweight materials and enhanced electronically controlled automatic transmissions enable greater fuel efficiency compared to older models.

Regular fuel efficiency assessments can help identify vehicles experiencing declining performance, allowing for strategic fleet upgrades. These investments lead to long-term fuel cost reductions and improved operational sustainability. 

Leveraging fuel-efficiency technologies

Advanced technologies are playing a key role in optimizing fuel consumption. Systems including eco-driving assistance tools and AI-based analytics platforms help optimize driving behavior in real time.

These solutions analyze vehicle operation data and provide practical recommendations for fuel-saving improvements. Furthermore, IoT (Internet of Things)-based telematics solutions enable continuous monitoring of vehicle conditions and fuel performance, ensuring efficient fleet management. 

Three key benefits of improving fuel efficiency in heavy-duty trucks

Significant cost savings

Enhancing fuel efficiency is one of the most effective cost-reduction measures in the transportation industry. For example, if a truck that drives 5,000 km per month improves its fuel economy from 4.0 km/L to 4.4 km/L, it can save approximately 110 liters of fuel per month.

For large fleet operators, these fuel savings translate into substantial financial benefits. Additionally, reducing wear and tear through eco-driving techniques leads to lower maintenance costs, contributing to overall profitability. 

Lower environmental impact

Improving fuel efficiency is a crucial step toward sustainable logistics. A 10% increase in fuel efficiency can reduce annual CO₂ emissions by approximately 6 metric tons per truck (depending on driving conditions and vehicle specifications).

This contributes significantly to global climate change mitigation efforts. Additionally, reducing nitrogen oxides (NOx) and particulate emissions helps improve air quality, further supporting environmentally responsible logistics operations. 

Enhanced safety and reliability

Fuel-conscious driving techniques also contribute to road safety improvements. Practices including minimizing sudden acceleration and braking and maintaining a consistent speed help reduce accident risks.

Furthermore, regular preventive maintenance ensures optimal vehicle performance and reliability. These efforts also lead to lower insurance costs and longer vehicle lifespan, enhancing overall operational stability and trustworthiness in the transport industry.

UD Trucks’ commitment to fuel efficiency innovation

As a leading commercial vehicle solutions provider, UD Trucks is dedicated to developing cutting-edge fuel-saving technologies. The company has designed high-performance, fuel-efficient powertrains, including the GH11 engine, which delivers a balance of power, efficiency, and reduced emissions, and the GH8 engine, known for its lightweight yet high-torque performance.

A key innovation is the 12-speed electronically controlled automatic transmission, ESCOT-VI, which features ECO Mode and ECO+ Mode, enabling optimized fuel-efficient driving based on road conditions. 

Through these technological advancements, UD Trucks is helping transport operators reduce operational costs and minimize environmental impact.

Fuel efficiency improvement: a step toward cost reduction and environmental sustainability

Enhancing fuel efficiency is critical for the long-term sustainability of the transportation industry. By implementing effective driving techniques, conducting regular maintenance, and leveraging the latest technologies, significant fuel savings can be achieved.

Fuel efficiency not only reduces costs but also contributes to environmental protection and enhanced safety. For the global logistics industry, fuel efficiency improvement is a vital step toward a more sustainable and responsible future.