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PepsiCo: CNG Case Study

PepsiCo: CNG Case Study Overview

This case study, provided by PepsiCo, highlights how CNG performed in the context of a full-scale rollout started in 2011 in the United States with Class 8 vehicles.

Part 1: Baseline Fleet and Technology

This section describes the characteristics of the existing technology in the fleet (i.e. prior to the test). This provides information on the fleet characteristics, duty cycle details, and region of operation for the technology being tested.

Company Name PepsiCo (Frito-Lay NA)

Vehicle Type Diesel tractors with a fuel economy of 6 miles per gallon

Fuel Type Diesel

Refueling Over the road

Average Vehicle Miles Traveled (VMT) 105,000 miles

Hours of Operation 2,650

Average Load 27,000 pounds payload

Maximum Load 48,000 pounds payload

Length of Haul 500 miles

Return to Base Yes

Country United States

City or Region Multiple

Lifespan 7 years

Description (optional) Average payload is outbound; return load is typically less; depending on configuration, range may exceed 700 miles


Part 2: Technology and Test Purpose

This section describes the type of technology tested and primary reasons behind the test.

Technology Tested Class 8 Tractor 12L CNG Engine, 9L CNG Engine, CNG Fuel Delivery System

Test Purpose * Obtain driver acceptance
* Better understand maintenance demands and best practices
* Learn vehicle performance of various duty cycles using multiple vehicle specifications
* Learn CNG fueling: network of stations, major partner agreements, and operations


Part 3: Test Parameters

This section describes the actual parameters used to test the new sustainable technology, including number of vehicles tested, testing timeline, additional training and infrastructure requirements, etc.

Sample Size 2 initially, then 16

Start Date 2011

Total Miles Tested More than 100 million miles to date

Maximum Load Tested Up to 80,000 pounds

Time to Fuel (in Minutes) 15 minutes at 3600 pounds per square inch for 175 DGE

Testing Barriers (optional) Infrastructure and availability of fuel, maintenance facility and capability, driver/technician education and training


Part 4: Supporting Services

This section describes the additional supporting services needed for the sustainable technology tested, including details on fuel type, infrastructure requirements, and personnel training.

Fuel Type CNG

Feedstock Average Pipeline Natural Gas (unspecified source)

Level of Readily Available Infrastructure Medium

New/Special Infrastructure Requirements Feasibility of fuel station (proximity, performance (flow rate), pricing, public access, pavement (room to maneuver)

Special Training Requirements Training maintenance (engine), tank inspection, safety (technicians, facility, drivers), operational training for drivers


Part 5: Operational Performance

This section describes the key metrics used to measure operational performance of the alternative fuel or technology, benchmarked against the current technology used in the fleet.

Driver Satisfaction Average

Special Training Requirements Fueling, operating, and safety for drivers, understanding fuel levels and range.
Training for mechanics, tools, equipment, facility, fuel system, fuel handling (high pressure system), tank inspections.

Special Maintenance Requirements Training for mechanics, tools, equipment, facility, fuel system, fuel handling (high pressure system), tank inspections.

Additional Benefits for Fleet Price per unit of fuel, less maintenance on emissions systems (no SCR or DPF).

Additional Challenges for Fleet Maintenance frequency, maintenance facility ventilation, maintenance technician capability, vehicle range (600-700 miles), fuel availability in emergency response situations (limited infrastructure), mostly limited to out-and-back routes, limited regions with fuel availability, residual value of the asset yet to be determined


Part 6: Financial Performance

This section describes company’s expectations for financial and economic performance of the technology, benchmarked against the incumbent fuel/technology. Where noted, minus (-) is savings and plus (+) is additional costs for the fleet.

Fuel Premiums/Savings Better than diesel

Maintenance Premiums/Savings Equivalent to diesel for life cycle

Capital Premiums/Savings More expensive than diesel; however, incentives available in some regions

Estimated Residual Value in USD$ TBD—not relevant to PepsiCo service life and not evaluated as part of case study

Did You Use Subsidies? Yes


Part 7: Conclusions

Will You Inlcude This Technology in Your Fleet? Yes

Additional Comments 12L CNG Engine and large capacity Fuel Delivery/Storage System (160 DGE): This technology has been adopted into the fleet, based on vehicle performance, reliability, environmental impacts, and cost. 9L CNG Engine – not incorporated into line-haul operations due to underperformance.

Would You Recommend this Technology for Other Fleets or Applications? Yes

Additional Comments Infrastructure widely available in some regions and growing in others, technology has been widely adopted, unlocks access to rCNG ; consideration should be given to transmission and capacity of fuel storage/delivery system onboard vehicle; CNG fuel tank location should be made based on maintenance costs, labor costs, plumbing complexity and safety. Quieter engine relative to diesel. Consider external maintenance for high pressure fueling system



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