6 ways to reduce fuel costs for HGVs (in road transport)

Fuel is one of the biggest costs in road transport today. If you run a transport company or manage a fleet, you know that every litre of diesel is not just a cost – it is also potential profit going up in smoke.

At a time when fuel prices are changing like a kaleidoscope and competition is hot on your heels, reducing fuel costs is not a luxury, it is a necessity. And while the fuel consumption of a tractor unit or the average fuel consumption of a truck depends on dozens of factors, from driving style to aerodynamics, many of these factors are within your control right now.

In this article, we will show you 6 specific ways to achieve lower fuel consumption and minimise costs in your transport company. No beating around the bush. No magic tricks. Just proven solutions that you can implement right away, regardless of how many trucks you have in your fleet.

Ready to stop burning through your budget at the petrol station and minimise your fuel costs? Let’s go.

Why are fuel costs so important in trucking?

In road transport, fuel is not just an operating cost – it is a key component of the profitability of the entire business. For many transport company owners, fuel costs can account for as much as 30-40% of total expenses.

What’s more, they are the ones who feel every penny that goes up at the petrol station.

What factors affect truck fuel consumption?

In theory, it’s simple: the heavier the load, the worse the road conditions and the more aggressive the driving style, the more fuel the truck consumes.

But in practice, there are many more factors that influence fuel consumption:

• Vehicle condition – e.g. clogged filters or incorrect tyre pressure can increase fuel consumption by several percent.
• Driving and road conditions – a large number of bends, driving on hilly terrain, in traffic jams or in the rain means higher fuel consumption.
• Vehicle load – the greater the weight of the load and/or its sub-optimal distribution, the more litres of fuel per 100 km.
• Truck aerodynamics – poorly fitted spoilers or a trailer that is too high increase air resistance and fuel consumption.
• Driver’s driving style – sudden acceleration, failure to maintain a constant speed and frequent idling increase fuel consumption.
• Vehicle emission class and engine power – older trucks with EURO 3 or lower standards often have higher fuel consumption than modern models that meet the EURO 6 standard. The differences can be as much as several litres per 100 km.

As you can see, fuel consumption is a complex topic, but one that offers plenty of opportunities for optimisation.

How much fuel does a TIR truck consume per 100 km? Examples and real figures

This is one of the most frequently asked questions in the industry. The answer? It depends – but there is a certain range. The average fuel consumption of a TIR truck usually ranges between 25 and 35 litres per 100 km, depending on:

• the total weight of the vehicle (e.g. a 40-tonne truck consumes more than a light car transporter),
• the type of fuel (e.g. diesel vs. compressed natural gas),
• the EURO standard and emission class of the vehicle,
• and, above all, the operating conditions and driving style of the driver.

For comparison: a EURO 3 tractor unit with a semi-trailer, carrying 24 tonnes of cargo, consumes on average approx. 30-35 litres per 100 km under standard conditions.

The same configuration, but with a EURO 6 tractor? The result drops to between 22 and 26 litres.

But all it takes is a poorly chosen route, overloading or aggressive driving and the result in both cases increases significantly.

So how much does a truck with a semi-trailer consume? As much as you allow it to.

6 effective ways to reduce fuel costs

Below you will find 6 specific, proven methods that help transport companies reduce TIR fuel costs and significantly improve fuel efficiency.

Some of them can be implemented immediately, while others require long-term fleet development planning and related investments.

1. Driving style makes a bigger difference than you think

It is not without reason that driving style is the number one topic in the context of fuel consumption. Even the best-optimised route will be useless if the driver accelerates and brakes abruptly, does not maintain a constant speed or uses neutral gear too often.

Estimates are clear: improving driving technique can reduce fuel consumption by up to 15%. Calculated over thousands of kilometres travelled by professional drivers, this amounts to hundreds of litres of fuel. And that means real money in the company’s pocket.

Eco-driving is more than just a buzzword. It is a set of specific techniques that you will really feel in terms of fuel savings:

• avoiding sudden acceleration and braking,
• maintaining a constant speed,
• using gears and engine braking appropriately,
• avoiding idling.

Each of these habits translates into lower fuel consumption and real savings.

That is why training drivers in eco-driving techniques is an investment that pays off faster than you think. A well-trained driver not only consumes less fuel, but also:

• takes better care of the vehicle,
• causes fewer breakdowns,
• reduces the operating costs of the entire fleet.

In companies that have implemented training programmes, average truck fuel consumption has fallen by as much as 2-4 litres per 100 km. These are long-term savings that really show up in the annual balance sheet.

2. Fleet cards and fuel discounts – a simple way to save money quickly

This is one of the easiest ways to reduce fuel costs without moving the vehicle from its place.

Fleet cards offer real discounts – often in the range of 10-40 pence per litre of diesel. With the scale of fleet refuelling, these few pence make a huge difference.

In addition, fleet cards allow you to:

• control driver expenses,
• reduce the number of invoices and accounting transactions,
• collect data for analysis,
• negotiate terms depending on the size of your fleet.

3. Regular maintenance and technical inspection of the vehicle

A neglected truck is a fuel-burning monster. An unadjusted engine, clogged filters, worn tyres and low tyre pressure all affect fuel consumption and can increase it by several or even tens of percent.

Regular inspections and servicing of your tractor unit are not a cost – they are an investment in lower fuel consumption and lower operating and repair costs in the future.

4. Intelligent route planning

You don’t need to be a mathematician to know that fewer kilometres driven means less fuel consumed. But good route planning is more than just shortening the distance.

With modern systems such as HOGS Maps, you can:

• avoid traffic jams and steep roads,
• choose routes with cheaper tolls,
• plan stops at places with cheaper fuel,
• avoid unnecessary detours.

The result? Lower fuel consumption, less fuel consumption and less stress for the driver.

➡Try HOGS Maps for 14 days free of charge and start saving today!

5. Optimise load weight and distribution

Vehicle load and weight have a direct impact on fuel consumption. This is nothing new, but many companies still load their trucks as if weight didn’t matter, even though it can significantly increase fuel consumption.

• Every extra tonne = higher fuel consumption.
• Poorly distributed load = greater resistance and higher diesel consumption.
• Overloading? Too much weight on the trailer? A simple way to increase operating costs and get a fine.

If you want lower fuel consumption, start with a lighter trailer, better planning and weight control.

6. Modern technologies for improving fuel efficiency

From aerodynamic covers to advanced engine management systems, today you really have a lot to choose from when it comes to fuel-saving technologies.

Among the solutions worth considering are:

• roof and side spoilers,
• predictive cruise control systems,
• real-time driving style analysis,
• fuel consumption monitoring via telematics systems.

All of this not only helps to significantly reduce fuel consumption, but also reduces exhaust emissions and vehicle operating costs.

Long-term savings – how to think strategically about fuel consumption?

A one-off cut in fuel costs is like putting out a fire with a cup of water – it helps for a moment, but soon everything will catch fire again. Real long-term savings require a strategic approach to the fuel efficiency of the entire fleet: from data analysis to driver culture and investment in technology.

Fuel efficiency is a marathon, not a sprint

Consistent, systematic actions yield the greatest returns:

• Monitor fuel consumption in real time – telematics and advanced fleet management systems show when a particular truck is consuming more fuel than it should. Data is essential for improving fuel efficiency and responding quickly to deviations.
• Set key KPIs – e.g. litres of fuel per 100 km for each type of route, tractor unit or driver. Clear goals motivate and make it easier to assess progress.
• Engine control unit (ECU) software updates – manufacturers release patches that can reduce fuel consumption by up to 2-3%. It is worth following service bulletins and updating vehicles during servicing.
• Fuel saving strategies should be part of your company policy – bonuses for the best fuel consumption results, driver rankings or internal training courses maintain high fuel efficiency/energy efficiency in the long term.

Fuel costs and the competitiveness of a transport company

Fuel is not just an expense – it is an advantage or a burden in the battle for customers.

• Lower cost per km = greater flexibility in freight rate negotiations. A company that can reduce its fuel costs can offer its customers a better price and still make a profit.
• Lower emissions are an argument in tenders with large contractors who loudly communicate their ESG goals. In CSR reports, the numbers speak for themselves.
• Long-term savings finance development – funds saved on fuel can be more easily allocated to modern fleets, fuel-efficient technologies or the expansion of the logistics network.
• Market reputation – customers are increasingly asking about a carrier’s carbon footprint. Declaring lower fuel consumption and providing real telematics data builds trust and sets a company apart from its competitors.

The result? A strategic approach to fuel consumption not only means lower bills at the pump, but also a real competitive advantage – it protects your margins today and opens the door to lucrative contracts tomorrow.

Summary

Fuel consumption is something you can really influence – every day, on every route. You don’t have to wait for better times or invest hundreds of thousands in new trucks. All you need to do is implement a few proven solutions – from eco-driving and route planning to the use of fleet cards – and your company will start consuming less fuel and reducing costs right away.

Remember: every drop of fuel saved is profit that stays in your pocket. It also means lower fuel consumption for your tractor unit and, in the long run, greater competitiveness.

Start by optimising just one of the measures mentioned in the article and watch your fuel balance change. Because every route can cost less. All you have to do is give it the green light.

Frequently asked questions (FAQ)

How much fuel does a truck consume per 100 km?

The average fuel consumption of a TIR truck depends on many factors, including the vehicle’s load, route, driving style, technical condition and emission class.

For the purposes of this article and for the sake of simplicity, we can assume that for a standard tractor unit with a semi-trailer carrying a load of approx. 24 tonnes, the average fuel consumption is between 28 and 35 litres per 100 km.

It is worth remembering that a poorly chosen route, excessive weight or higher fuel consumption due to uneconomical driving can increase fuel consumption to over 40 litres per 100 km.

How much fuel does a truck consume when stationary? How much fuel does a truck consume when stationary?

Even when the vehicle is stationary, the engine is still running, which means fuel is being consumed. A truck consumes an average of 2 to 3 litres of fuel per hour when stationary with the engine running.

In the long run, this is a real cost: 4 hours a day of idling can amount to as much as 60 litres of fuel per week. That is why it is so important to avoid unnecessary engine operation when stationary.

At what speed does a truck consume the least fuel?

The optimum speed is the speed at which the truck moves smoothly, without unnecessary acceleration and braking. This is usually 70-85 km/h in road conditions conducive to maintaining a constant speed.

Driving above 90 km/h rapidly increases fuel consumption due to greater air resistance. In practice, the difference between driving at 85 and 95 km/h can be as much as 2-3 litres per 100 km. That is why maintaining a constant, moderate speed is one of the key strategies for saving fuel.