Rail

Colas Rail | 4-7% Average Fuel Savings

Colas Rail deployed FuelActive across fleets, cutting contamination, reducing fuel use, lowering emissions, and improving reliability to meet sustainability targets.

Proven results

7% 4–7 % average fuel savings across fleet
365T CO₂ reduction annually
4x longer fuel filter lifespan

The Challenge

Colas Rail UK spends around £1.8m annually on diesel, producing nearly 5,000 tonnes of CO₂. The company was seeking proven solutions to lower fuel consumption, cut emissions, and protect sensitive engines from contamination. Frequent filter changes and injector issues were driving costs and downtime.

With 90% of UK rail freight still diesel-powered, Colas Rail needed a practical technology that could deliver measurable results immediately, while supporting long-term sustainability commitments.

The Solution

FuelActive worked with Colas Rail, Unipart Rail, Network Rail, and Cummins to run robust pilot trials across grinders, tampers, and millers. Using OEM telematics, trials across eight engines delivered 4–7% average fuel savings, with maximum savings of 12.3% on certain machines.

The technology proved simple to install, typically under an hour per engine, and scalable. Following trials, Colas Rail rolled out FuelActive across its entire on-track maintenance fleet, plus Class 37 and Class 66 freight locomotives.

The Solution
"We are seeing 4–7% average savings. Reliability has improved with fewer injector issues and four times the filter life."

Dan Bird, Maintenance Manager, Rail Profile Treatment Fleet, Colas Rail UK

The Benefit

Cleaner fuel extended filter life up to four times, reduced injector issues, and improved overall engine reliability. With savings of up to £6,800 per train annually, return on investment was less than a year.

The technology has now been endorsed across Colas Rail UK and is being reviewed by Colas France, Colas Eastern Europe, and global partners such as Loram. The proven scalability of FuelActive highlights its potential to decarbonise rail, construction, and power fleets worldwide.

The Benefit

The Outcome

Fuel economy

4–7% average savings, up to 12.3% in trials.

Cost saving

£3,900–£6,800 per train annually, plus £1,750 filter savings.

Sustainability

365 tonnes CO₂ reduction projected across fleet.

Reliability

4× filter life and fewer injector issues.

Driving carbon reduction in rail

See how FuelActive helps operators cut costs and emissions across maintenance fleets and freight locomotives.

Driving carbon reduction in rail