United Parcel Service (UPS) is redesigning its familiar brown delivery trucks with plastics to save up to 40 percent in fuel costs compared to the standard aluminum-body vehicle. The company expects to achieve this goal by replacing metal truck bodies with composites and other plastics, which will lighten their weight by 900 pounds. It plans to buy 150 new trucks with the plastic bodies, with delivery slated for the fourth quarter of this year.
UPS has been testing the concept during a year-long pilot program that let the company try out the structural strength, durability, and repair qualities of the new truck design's materials. The tests involved using the program's five CV-23 prototype package cars from specialty truck maker Utilimaster in difficult settings. The trucks' composite plastic bodies proved to be durable and easily repaired or replaced since components are modular and don't require body work. The vehicles worked well in a variety of climates, which is especially important in areas where corrosion from road salt is an issue. Tests were conducted on rough back roads in Lincoln, Neb., winter conditions in Albany, NY, desert heat in Tucson, Ariz., high mileage in Acworth, Ga., and a long urban route in Flint, Mich.
United Parcel Service is planning to shift to composites and other plastics for many of the structural components in its brown delivery trucks, as shown in this prototype. (Source: UPS)
UPS said the fuel savings of 40 percent rivals the amount of fuel that could be saved by using alternative fuel vehicles, but without the challenges that accompany a shift to those vehicles. These include fueling infrastructure issues and threats of technology obsolescence, as well as production challenges.
Composites used in the test trucks' hoods and roofs are reportedly fiberglass-reinforced plastic. Other plastic components include lower body panels, front fenders, front bumper cover, and dashboards made of injection-molded polyurethane. The instrument panel and interior cabin trim are made of thermoplastic olefin, as well as some structural components made of polyethylene sheet-molding compound.
In the past, UPS had experimented with a limited amount of composites use in vehicles. The current delivery truck design extends the materials across the entire vehicle, except for the floor. Although test trucks had a composite floor, metal floor structures will continue to be used to provide enough strength for supporting the weight of the truck's contents. The new truck is also somewhat smaller than the previous aluminum versions at 630 cubic feet, which is about 70 cubic feet less of interior cargo space than the standard P70 aluminum truck.
The company's next step is to test the same materials in larger, heavier vehicles to determine how well they work. UPS is working with several vehicle manufacturers in an attempt to cut vehicle weight, improve miles per gallon, and increase fuel efficiency by a number of different methods, including structural and operational approaches. Other design changes to existing vehicles include prototype hoods to improve aerodynamics, perforated mud flaps on tractor-trailers for reducing wind resistance, and using telematics to help reduce miles traveled to deliver packages. UPS also has more than 2,500 alternative fuel and advanced technology vehicles in service.
I've always admired the UPS way of continuously and effectively improving their processes and equipment to find new and innovative ways to squeeze additional profits from a their business. 'Brown' is not the most glamourous company, but they continue to impress me with their forward thinking improvements such as this one.
Good point. If it is possible, then all of them should use it. The fact it will be done here is a big plus for our own workforce. Lets hope they do it.
Hopefully, these new truck designs can migrate their way to other delivery services like FedEx. If it does, I hope that the Fuel Surcharge that now is part of the shipping costs start to reduce.
Very often, roads in developing countries, such as India or Nigeria, are consistently in various states of disrepair. Lighter vehicles lead to fewer potholes and damage to roads. Here in California, there have been debates to make parts of I5, in Los Angeles, semi-truck free in order to lessen the cost of constant repair due to heavy trucks.
If the cargo weight remains the same but the vehicle weight is lighter, it's a small step in the right direction.
And, if the new UPS vehicles are manufactured locally, even better. Other companies could benefit from the technology.
40% fuel savings after 900 pounds reduction in weight is remarkable. Really makes you rethink the whole alternative fuel programs. If that is indeed the case, then congratulations to UPS, but even more so to the Truck Maker, UtiliMaster. The list of items that underwent experimental material updates is lengthy, and they should be recognized for that engineering effort.
Now, I wonder if they are locked to an exclusive with UPS to distribute the vehicles --- or, are able to market their new success to other freight companies, DHL, FEDEX, etc-? It all depends on who paid for the light-weight materials research. Ann Thryft mentioned some bit of insight to that query ,,,,,,
@NadineJ: Why do you think these trucks would be better for developing countries? I'm not disagreeing with you, but I'm not sure I understand your reasoning.
A 40 percent savings is significant and impressive. It's hard to believe that plastics and composites are that much lighter than aluminum. Any word on the durability and crash resistance with the new materials?
Agreed that these are very good for US urban markets but also good for international cities with older roads. The mass retail expansion from the west into India, for example, will require more international shipments. I wouldn't want to be on a road in Mumbai along side one of the current UPS trucks.
Now, they need to update the uniforms and logo. I'm inspired!
Beth, thanks for that input about other mass transit and delivery projects using new materials. UPS is certainly not alone: the company building these trucks, Utilimaster, has made similar delivery vehicles for other companies, including Federal Express.
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