MVT Solutions Certified™ testing found the Energy Guard Aero Flap improved fuel economy 0.90% (0.08 MPG) when installed on a modern sleeper cab tractor and 53-foot dry van trailer. Testing was conducted on a closed 9-mile circular test track in Pecos, Texas, at a controlled speed of 65 miles per hour and a gross vehicle weight (GVW) of approximately 45,000 pounds.
How it Works
The Energy Guard Aero Flap is an aerodynamic enhancement system designed to reduce fuel consumption by minimizing the drag created by traditional mud flaps. This system replaces OEM mud flaps with specially engineered flaps that streamline airflow around the wheels of both the tractor and the trailer. By improving the aerodynamic profile of the vehicle, the flaps reduce resistance and help lower diesel fuel usage. The design requires no power source or active components, making it a passive and low-maintenance solution that is compatible with a wide range of Class 8 tractors and trailers. The Energy Flap is a simple retrofit that can be installed fleet-wide without requiring structural modifications to the vehicle.
Test Results
The test was conducted using two identical 2019 International LT 625 tractors, each pulling a 53-foot Hyundai dry van trailer outfitted with side skirts. Both vehicles were equipped with Cummins X15 15-liter engines and Eaton Endurant 12-speed automated manual transmissions. One unit was designated the Test Vehicle and outfitted with Energy Flaps on both the tractor and trailer, while the second unit served as the Compare Vehicle and retained standard OEM mud flaps throughout the test. The vehicles were driven simultaneously on the track, spaced one minute apart to eliminate aerodynamic influence between them. Fuel consumption data was gathered using advanced race car-grade sensors and a proprietary data acquisition system developed by MVTS. The final results showed that the Energy Guard Aero Flap reduced fuel usage by 0.97 gallons per 1000 miles, equating to a 0.90% improvement in fuel economy compared to the baseline configuration. MVTS calculated the accuracy of this test using a 95% confidence interval, yielding a margin of error of +/- 0.54 gallons per 1000 miles. These results are considered highly reliable and reflect real-world potential savings for fleet operations.
Savings Potential
The Energy Guard Aero Flap demonstrated significant potential for reducing operational costs. For a fleet vehicle traveling approximately 125,000 miles per year, the observed savings of 0.97 gallons per 1000 miles would translate to an annual fuel savings of 121 gallons. Using the U.S. average diesel retail price of $4.214 per gallon, this results in a cost savings of approximately $510 per year per vehicle. At an estimated cost of $180 for the Energy Flap system per vehicle (based on six flaps per tractor-trailer combination), the investment would pay for itself within 8.5 months. Over a five-year period, this would amount to a net profit of $4,740 per vehicle, and for a fleet of 1,000 trucks, a total fleet profit of $4.74 million. In addition to financial benefits, the fuel savings correspond to an annual reduction of approximately 1.23 metric tons of carbon dioxide emissions per vehicle, further enhancing the environmental value of the technology.
Independent Third-Party Testing
MVT Solutions fuel economy testing is fully independent and unbiased. The organization does not receive compensation from the sale of any products it tests. All testing is performed using MVTS proprietary methods developed through over a decade of experience and based on race car engineering principles. Each vehicle is equipped with high-precision sensors that capture real-time data on fuel consumption, tire temperature, wind resistance, and other variables that influence performance. MVTS’ test methodology ensures that results are accurate, repeatable, and directly applicable to real-world fleet operations. Fleets interested in this product or wishing to view the full report may contact MVTS or visit their website for additional details.
