Diesel Fuel Atomization: #1 Way to Cut Heavy-Equipment Costs
Fuel Atomization Most Efficient Means of Reducing Fuel Consumption
The most advanced and precise formula for calculating heavy-equipment costs is the Peurifoy and Schexnayder Method (PSM). Studying PSM, construction and development companies and owners/operators can quickly estimate heavy equipment costs. Understanding what costs they have, allows heavy equipment companies and owner/operators to determine what costs to cut.
There are — theoretically — a large number of costs heavy-equipment companies and owner/operators can cut. However, all but one requires companies and owners/operators to sacrifice fleet or production quality.
Fuel costs are the only expense heavy-equipment companies and owner/operators can reduce without buying or producing an inferior product.
Reducing Diesel-Fuel Consumption Does Not Require Sacrificing Quality
With the exception of diesel-fuel consumption reduction, every heavy-equipment cost-cutting approach hurts quality in one respect or another. With regard to purchasing heavy equipment and heavy equipment parts, cheap is rarely inexpensive. Cheap tires, for example, don’t typically last as long as high-quality, more expensive tires. That means replacing the tires more often. That equates to a profit loss over the long run.
The same can be said for oil and lubrication. The same can be said for purchasing a less expensive machine make or model. Cutting costs by purchasing cheap machines, parts or fluids requires a company or owner/operator sacrifice quality.
With respect to hiring employees, the same can be said.
Hiring less experienced operators in order to cut wage costs means paying for mistakes, damage, and inefficiency. Cutting costs by offering operators fewer benefits means having the inability to attract the best talent.
Every cost in the Peurifoy and Schexnayder Method of estimating — if cut — leads to lower quality or greater inefficiency. Every cut requires a company to sacrifice quality or efficiency. In order to reduce the discrepancy between gross income and net income, sacrificing quality is a requisite.
There is only one exception: fuel consumption reduction.
Increasing Operator Efficiency
Diesel fuel costs are the second most expensive operating cost companies and owner/operators incur. Only the cost of operator wages is more expensive than fuel costs according to the Peurifoy and Schexnayder Method. And when diesel prices are high, fuel costs and wages are almost equal.
Knowing this, the heavy-equipment technology industry developed a number of devices specifically designed to reduce diesel fuel consumption. The assumption heavy-equipment technology companies make — all but a few — is that idle time is the biggest waste of fuel. The assumption is, by reducing idle time, a company or owner/operator can reduce diesel fuel costs.
GPS Machine-Tracking Devices
In order to minimize idle time, heavy-equipment technology companies developed tracking devices that can monitor a machine. Heavy-equipment GPS tracking devices can monitor machine movement, machine speed, and engine RPM.
Heavy-equipment GPS trackers can also log load weight, control implement elevation, as well as a variety of other operational actions. All are factors in fuel consumption efficiency.
By logging and analyzing the data from a GPS tracking device, a company can evaluate efficiency over time. A company can determine how much fuel is wasted each day, week, month, and year.
The problem with GPS machine-tracking devices, however, is that they do not directly lower fuel consumption. A tool used to track fuel waste; GPS tracking devices are only useful for creating company regulations, policies, and procedures.
In the end, an operator must make decisions that reduce idle time. Machine tracking devices are not capable of preventing diesel fuel waste, only monitoring it.
Technologies that Control Idle Time
Technology can be a means of removing machine operators from the idle-time inefficiency equation altogether. Technologies like idle reduction mechanisms remove the human element from idle time. These devices reduce engine RPM when an operator does not manipulate a lever within a given period of time. So, even during idle time, less fuel is burned.
For example, a roller packer operator removes his foot from the accelerator and allows the machine to stop. If the operator does not engage the machine within five seconds, for example, the idle reducer drops the engine RPM.
Even if the engine speed lever is still engaged at a high RPM, the idle reducer slows the engine.
But, engine idle reducers only work on a select few machines, those with engine speed levers or selector switches. Idle reducers serve no purpose on machines like loaders and graders that do not have engine speed levers or switches. Furthermore, idle reducers do not stop fuel burn during idle time. Idle reducers merely reduce the amount burned during idle time.
Atomization: Increasing the Energy Output of Diesel Fuel
Lowering fuel consumption with engine idle reducers and GPS machine-tracking devices cut costs by minimizing operator inefficiency. Productivity increases with the minimization of the human element of fuel consumption.
Atomizers, on the other hand, increase the efficiency of diesel fuel by increasing the energy output of each unit of measure. Atomizers increase production efficiency by making each gallon or liter of fuel more productive.
Rather than spending human or mechanical resources on the increase of operator efficiency, atomizers increase production efficiency by making each gallon or liter of fuel produce more energy.
Fuel is saved regardless of whether or not an operator follows best-practices protocol.
Technologies that Increase the Energy Output of Fuel
There are two types of technologies that increase the energy output of diesel fuel. Both are atomizers which means they increase the burn percentage of each unit of fuel. Naturally, diesel fuel is not a uniform, homogeneous mixture. Instead, on a microscopic level, it is a soup of molecular clusters.
The larger the diesel-molecule clusters, the less efficient the fuel burns in an engine cylinder. In other words, atomizers minimize the amount of unburned diesel fuel that escapes out the exhaust.
Rentar Fuel Catalyst
A pre-combustion atomizer, the Rentar Fuel Catalyst, reduces diesel fuel consumption between 3% and 8% on heavy equipment and trucks. On marine engines, the fuel savings are even higher. A Rentar Fuel Catalyst on a furnace or boiler reduces fuel consumption by up to 30%.
The Rentar Fuel Catalyst is a mechanical device placed on the fuel line. Precious metals in the Rentar cylinder break up molecular clusters in diesel fuel. The homogeneous diesel mix the Rentar produces leads to a far more efficient and clean fuel burn.
So effective is the Rentar Fuel Catalyst that Rentar guarantees a return on investment within 12 months.
Maybe the only of its kind in the construction/development industry, the Rentar has a 10-year warranty.
Still, in the development stage, high-pressure injectors are available on a limited number of machines. In an effort to further accentuate the atomizing action of traditional injectors, high-pressure injectors force diesel fuel into the cylinders of an engine at almost 10 times that of conventional diesel fuel injectors.
Though expensive, once high-pressure injectors are capable of functioning without damaging an engine, there will be potential for significant fuel savings.
Limited Cost-Cutting Options Does not Mean Limited Savings
While the most effective and efficient means of cutting operational costs — reducing fuel consumption — is limited by a small number of options, that does not mean those options cannot amount to considerable savings.
Atomizers, GPS machine tracking systems, and heavy equipment idle reducers can equate to substantial savings.