How Fuel Ox® with Combustion Catalyst Helps Fleets Save Over $500K Annually

In the world of diesel fleet operations, profits are often won or lost in the margins. One extra regen, a fouled sensor, or a clogged DPF can snowball into thousands in downtime, repair costs, and inefficiencies. Multiply that across an entire fleet, and the numbers get serious fast.

That’s why more fleet operators and owner-operators are turning to Fuel Ox® with Combustion Catalyst, a next-generation fuel additive that tackles the root causes of soot and emissions system failure, not just the symptoms. Let’s take a closer look at the hard financial case behind this solution, backed by real numbers, conservative modeling, and years of on-road performance.

The Diesel Dilemma: Clean Emissions, Dirty Costs

Modern diesel engines are engineering marvels. Equipped with Diesel Particulate Filters (DPF), Exhaust Gas Recirculation (EGR) systems, and SCR/DEF emissions controls, they meet ever-stricter environmental standards while delivering powerful performance. But all that hardware comes at a price, especially in maintenance.

These systems trap soot, regulate exhaust gases, and inject diesel exhaust fluid (DEF) to reduce emissions. However, when soot builds up faster than it can be burned off through regeneration, fleets start paying the price in:

• Increased fuel consumption
• More frequent DPF cleanings and replacements
• EGR fouling and sensor failures
• Regeneration-related downtime
• Higher DEF usage

And even with conventional additives, detergents, lubricity enhancers, stabilizers, these downstream problems persist because the combustion event itself hasn’t changed.

Enter Fuel Ox® With Combustion Catalyst: A New Class of Additive

Fuel Ox® with Combustion Catalyst stands apart from traditional fuel treatments by altering the combustion process at the molecular level. Rather than just cleaning injectors or preventing water buildup, our proprietary additive changes how fuel burns.

How? By lowering the activation energy of combustion. That results in a more complete, efficient burn, which means less soot formed in the first place. Less soot means fewer regens, fewer system failures, and longer service life for DPF and EGR components.

Unlike cetane boosters that shorten ignition delay but leave soot formation largely unchanged, Fuel Ox® catalytically reduces the very source of the problem. It’s a step-change in how we think about diesel fuel treatment.

Crunching the Numbers: A 100-Vehicle Fleet Case Study

The case study modeled a fleet of 100 Class-8 tractors or heavy-duty transit buses, each driving 75,000 miles per year with an average fuel economy of 6.5 MPG. Using conservative assumptions and real-world cost benchmarks, Fuel Ox® With Combustion Catalyst delivers savings across nearly every operational category. Let’s walk through the highlights:

• Fuel economy increases by 5%, saving approximately $2,019 per vehicle annually.
• DEF usage drops 15%, resulting in another $156 in savings.
• Sensor-related maintenance drops 80%, saving $960 per vehicle.
• Regens drop by 70%, saving $749 annually in time and fuel.
• EGR-related repairs decline 70%, saving $840.
• DPF cleaning intervals double, cutting those costs nearly in half.
• Unplanned emissions downtime is nearly eliminated, recapturing $640 per vehicle per year.

Altogether, these categories add up to $5,989 in annual savings per vehicle, offset by a modest program cost of just 1% of fuel spend (about $404), yielding a net gain of $5,585 per truck.

For a 100-vehicle fleet, that’s over $558,000 in net savings every year. Even better? The return on the additive investment is about 15x, with instant payback.

Why Conventional Additives Can’t Compete

Most fleet managers are familiar with traditional additives. They’re effective, to a point. Detergents, demulsifiers, lubricants, and stabilizers all help optimize fuel cleanliness and system health. But they don’t change combustion.

That’s why even when you treat your fuel, the soot keeps coming. Filters keep clogging. Sensors keep failing. Regens keep eating into uptime.

Fuel Ox® With Combustion Catalyst includes all of those housekeeping additives, and adds a combustion catalyst, plus a maintenance-level biocide to keep tanks clean. The result is a fundamentally cleaner burn and a cascade of downstream benefits that conventional formulas simply can’t match.

What Fleets Are Seeing in the Field

After switching to our formula, fleets consistently report a noticeable decline in maintenance burdens. One of the first things operators notice is how much longer they go between regenerations. Passive regeneration becomes more effective because soot levels never reach critical thresholds.

You also see more stable EGR outlet temperatures and less fouling, which means cooler components, fewer failures, and longer life. Sensor error codes and DEF dosing events start to drop off. And because engines run cleaner, downtime related to emissions faults becomes a rarity rather than a routine headache. In short, trucks spend more time on the road, and fewer hours in the shop.

How to Implement Fuel Ox® Across Your Fleet

Fuel Ox® is designed for easy adoption. No special equipment. No downtime. No expensive onboarding process. You simply add the additive at a 1:10,000 treat rate, one gallon treats 10,000 gallons of fuel. Bulk tank dosing is ideal, but at-nozzle dosing works for smaller operations or mixed fueling environments. 

It’s compatible with diesel and other middle distillates (including gasoline), provided they meet local specifications. We recommend starting with a small test group, say 10 vehicles, and tracking:

• Miles per gallon (MPG)
• Regeneration counts and durations
• DEF consumption
• DPF delta-pressure and cleaning intervals
• EGR and sensor maintenance orders
• Downtime incidents

Compare those metrics over a 4–8 week period against a control group or your pre-trial performance. Once you see the difference, it becomes easy to scale site by site.

Owner-Operator Impact: One Truck, One Big Win

For owner-operators, Fuel Ox® With Combustion Catalyst offers a meaningful income boost without a single mechanical upgrade. Based on the same model, a single truck driving 75,000 miles per year nets nearly $5,600 in annual savings, after accounting for the additive cost.

This isn’t just theoretical. Even modest improvements in MPG, DEF usage, and maintenance frequency translate into more take-home pay. Whether you’re running a small fleet or a solo rig, this is a performance upgrade that pays for itself, and then some.

The Bottom Line: Cleaner Burn, Higher Return

Our Fuel Ox® with Combustion Catalyst additive isn’t a feel-good idea. It’s a hard-numbers solution to a hard-numbers problem. It delivers better fuel economy, longer-lasting emissions components, reduced downtime, and fewer maintenance headaches, all with a simple additive that costs just a fraction of what it saves.

In conservative terms, a 100-truck fleet stands to gain over half a million dollars in annual net profit. Owner-operators can add $5,000 or more per year to their bottom line. And fleets of any size get to skip the pain of frequent regens, sensor issues, and DEF burn.

Try It and See for Yourself

Fuel Ox® with Combustion Catalyst isn’t just another additive on the shelf, it’s a proven tool for transforming how diesel fleets manage fuel, maintenance, and operating costs. By targeting the root of the problem, soot formation inside the combustion chamber, it delivers meaningful reductions in regens, DEF usage, and costly emissions-related repairs. 

The numbers don’t lie: whether you’re an owner-operator looking to boost annual profits or a fleet manager aiming to cut six figures in expenses, our industry-leading additive offers a fast, measurable return with virtually no operational disruption. It’s smart, scalable, and backed by real-world performance. If you’re serious about making your fleet run cleaner, longer, and more profitably, Fuel Ox® is the clear next step. Contact us today to learn more.