FlowBelow Aero
New FlowBelow AeroFender saves fleets 1.44% in fuel: Independent testing confirms

FlowBelow’s new AeroFender proven to save fleets 1.44% in fuel

April 1, 2024
Independent testing confirms that FlowBelow’s new AeroFender saved 1.49 gallons of fuel for every 1,000 miles driven, or 187 gallons over the course of 125,000 miles.

FlowBelow Aero, a tractor and trailer aerodynamic technology developer, recently introduced its AeroFender. The newest product in FlowBelow’s aerodynamic equipment lineup, the AeroFender, has been tested and is now widely available at OEM mod centers for installation on new trucks, directly from FlowBelow or through the OEM dealer network for retrofit applications.

The AeroFender reduces drag on day and sleeper cabs and is another tool for fleets to improve fuel economy and reduce CO2 emissions. The device provides the same safety and operational benefits as a traditional quarter fender but enhances fuel efficiency by redirecting the airflow ahead of and around a power unit’s leading drive axle. 

At a controlled track test completed in November 2023 by Mesilla Valley Transportation Solutions, the technology was proven to save 1.49 gallons of fuel for every 1,000 miles driven or 1.44% overall. Fleets can expect a truck with an AeroFender installed and traveling 125,000 miles per year to save an estimated 187 gallons of fuel.

At 22.5 pounds of CO2 per gallon of diesel fuel, a fleet of 1,000 could reduce CO2 emissions by as much as 4,207,500 pounds or 2,103.75 tons. In addition to the associated fuel savings and environmental upsides, FlowBelow calculates that the ROI on its AeroFender will come in under one year from the date of its installation.

See also: Increase fuel efficiency through aerodynamics

McLane Company has been a user of FlowBelow’s Tractor AeroKit and trailer wheel covers for some time. In 2021, the fleet was an early adopter of the AeroFender before its release to the industry.

“After extensive durability testing and ROI cost analysis, we began putting FlowBelow AeroFenders on our fleets in 2021,” said Daniel James, director of transport and tech at McLane. “The technology has proven itself over many years and millions of miles. We continue to spec it on all new vehicles to help us save fuel and reduce the environmental impact of our fleet.”

McLane proved to be an ideal test case for the AeroFender. The exposure to various drivers, environmental factors, and driving conditions provided valuable insights and solidified FlowBelow’s confidence that the AeroFender would attract fleets.

“We have over 1,200 units in the field, and we’re excited to begin offering it to a broader spectrum of fleet customers,” said Josh Butler, FlowBelow president and CTO. “We believe it will offer great appeal to LTL and day cab fleets, a market sector that has not traditionally been as likely to utilize our flagship Tractor AeroKit. The AeroFender is extremely durable, easy to install, and a smart upgrade to a component that these fleets are already buying.”

As a final step, FlowBelow conducted independent testing that would add an objective point of view and statistical analysis to the equation. It chose Mesilla Valley Transportation Solutions, a provider of fuel economy testing and design and development services for the trucking industry, to put the AeroFender through its paces.

“FlowBelow’s mission is to help save fleets 500 million gallons of fuel by 2030. Introducing the AeroFender makes that goal more attainable,” said Ted Simmonds, CEO of FlowBelow. “New product innovation is what drives us. We focus our efforts on developing products that not only help fleets save fuel but also help them advance their sustainability objectives.”

About the Author

FleetOwner Staff

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Kevin Jones, Editorial Director, Commercial Vehicle Group

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