Mafube Coal | 6.9% Fuel Saving
Mafube Coal trialled FuelActive on Komatsu trucks, proving 6.9% fuel savings and rolling out across the entire mining fleet.
Proven results
The Challenge
Diesel is one of the largest costs for Mafube Coal, with mobile equipment consuming the majority. The mine, a joint venture between Thungela and Exxaro, set a clear goal: cut fuel use and reduce its carbon footprint.
FuelActive was introduced through Exxaro HQ’s Innovation Department, following a connection from Axora, a leading mining marketplace. With Mafube’s Digital & Innovation Team driving the project, the trial was designed to meet sustainability KPIs and deliver measurable savings.
The Solution
A three-month trial was run with three Komatsu 730E haul trucks fitted with FuelActive and three kept as controls. Weekly data showed FuelActive-equipped trucks consistently outperformed the control group and historical averages.
To validate results, hypothesis testing was applied to the dataset, confirming the savings. Additional fuel sampling showed that engines were receiving cleaner, less contaminated fuel — strengthening the link between improved fuel quality and reduced consumption.
“FuelActive delivered proven efficiency gains in our haul trucks, supported by validated testing and fuel sampling. The rollout across our fleet will deliver measurable financial savings and a major contribution to our carbon reduction goals.”
Mafube Digital & Innovation Team
The Benefit
The results convinced Mafube to move immediately from pilot to full fleet installation. Working with subcontractor Gridlock, FuelActive has now been fitted across dozers, haul trucks, drills, and excavators.
The average 6.9% saving represents a major reduction in diesel consumption and CO₂ emissions. With fuel spend among the mine’s biggest costs, the financial and environmental impact will be significant, and Mafube plans to publish a technical paper on the results.
The Outcome
Fuel economy
Cleaner combustion improves fuel efficiency.
Cost saving
Fewer callouts, filter changes, and repairs.
Sustainability
Reduced fuel waste and emissions.
Reliability
Fleet-wide reduction in fuel-related breakdowns.
Mining cleaner, mining smarter
See how FuelActive is helping mines reduce costs, cut emissions, and keep equipment running at peak efficiency.
