How a 30-Truck Mining Operation Saved $1.1 Million a Year on Fuel
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Industry: Mining | Fleet size: 30 haul trucks | System: Fast Fill Systems Pressureless Tank System | Result: $1,100,000 estimated annual savings
The Problem
Fuel spills are easy to overlook on a busy job site — until you do the math.
A mining operation running 30 haul trucks was losing approximately 5 gallons of diesel fuel every time a truck was filled. With 4 fills per truck per day across a fleet of 30, that added up fast:
- 600 gallons spilled daily across the fleet
- 218,400 gallons lost annually — fuel that was purchased and never used
- 12 fuel tanks damaged each year from overfilling, each requiring repair or replacement
- Ongoing cleanup costs, safety risks, and regulatory exposure from fuel spills on site
The root cause was simple: no automatic shutoff. Fuel kept flowing past full. Operators couldn't watch every fill. Spills became routine.
The Solution
The operation installed Fast Fill Systems Pressureless Tank Systems across all 30 haul trucks.
The pressureless system uses a level controller and automatic shutoff valve to stop fuel flow the moment the tank reaches capacity — with no manual intervention required. A 3-micron filter keeps contaminants out of the fuel supply during every fill. The system installs directly into the existing tank fitting and works with standard fueling nozzles and receivers.
No pressure required. No float to fail. No operator error.
The Results
After installation across the fleet:
- Zero overfill spills — automatic shutoff eliminated the problem entirely
- 218,400 gallons of diesel recovered annually — fuel that previously hit the ground now goes into the tank
- 12 fewer tank damage incidents per year — no more overfill pressure events
- Reduced maintenance downtime — less cleanup, fewer repairs, more trucks running
- Improved site safety and cleanliness — fuel spills create slip hazards, fire risk, and environmental liability
Conservative estimated annual savings: $1,100,000
The Math
| Factor | Numbers |
|---|---|
| Trucks in fleet | 30 |
| Fills per truck per day | 4 |
| Gallons spilled per fill | 5 |
| Gallons spilled daily | 600 |
| Gallons spilled annually | 218,400 |
| Diesel cost (conservative) | ~$3.50/gal |
| Fuel cost recovered | ~$764,400/year |
| Tank damage incidents eliminated (12/yr) | Additional savings |
| Cleanup, labor, downtime savings | Additional savings |
| Total conservative annual savings | $1,100,000 |
What This Means for Your Operation
If your fleet is running manual fills without automatic shutoff, you're almost certainly losing fuel — even if no one's tracking it.
The pressureless system pays for itself quickly. For a 30-truck operation, the ROI is measured in weeks, not years.
Fast Track Fueling carries the full Fast Fill Systems pressureless lineup:
- Pressureless Level Controller | PLA150-M VLCE
- Pressureless Shut-Off Valve | PLA150-M SV
- Full Pressureless Kit | PLA150-K1 IO
- Pressureless System Fuel Receiver
Have questions about speccing a pressureless system for your fleet? Contact our team — we'll help you size the right setup.
📞 801-477-4358