https://nacfe.org/research/run-on-less/messy-middle/operations-report/

Terrain, Technology, and Telematics: The Messy Middle Operations Report

Run on Less – Messy Middle measured real-world performance from 14 Class 8 tractors operated by 13 participating fleets across four energy pathways: diesel/renewable diesel/biodiesel, compressed natural gas/renewable natural gas, battery electric, and hydrogen fuel-cell.

The Terrain, Technology, and Telematics: The Messy Middle Operations Report covers operational factors of Run on Less – Messy Middle including detailed specs of each truck, operating characteristics and focuses on the impact of speed, terrain and elevation on the freight efficiency of each truck.

NACFE’s mission is to help fleets invest in cost saving technologies that improve efficiency and reduce emissions. Taken together the three reports from Run on Less – Messy Middle on operations, total cost of ownership and emissions have brought clarity to long-haul. Using the three reports together should give fleet managers a clear path for making decisions on which efficiency technologies are best suited for their operation.

Run on Less – Messy Middle confirmed that freight decarbonization is not a simple technology swap but rather a complex, multi-decade transition requiring operational adaptation, infrastructure development, and technology-specific deployment strategies. The 13 fleets and 14 trucks demonstrated that each powertrain technology has a legitimate operational envelope where it can deliver competitive performance today — and equally, boundaries beyond which it struggles to match conventional operations.

After analyzing the data, the study team came to the following conclusions.

1. Diesel remains the operational benchmark. The diesel fleets achieved efficiency levels nearly double the typical long-haul fleet average — up to 11.8 MPG compared to approximately 6 MPG — while maintaining 500 to 800+ mile daily productivity across varied terrain. This performance, combined with ubiquitous infrastructure, establishes context for evaluating alternative powertrains. Renewable diesel provides a near-term decarbonization option (50% to 80% carbon intensity reduction) using existing assets and infrastructure.
   
2. Terrain is the most significant performance variable. Diesel demonstrated terrain resilience with approximately 30% efficiency variation between flat corridors and mountain passes. BEVs showed greater sensitivity, with efficiency variations of 50% to 70% across comparable terrain differences, translating directly to range variation. Route-specific terrain analysis is essential before deployment decisions.
   
3. CNG/RNG serves specific duty cycles well. The Cummins X15N natural gas engine demonstrated diesel-competitive pulling power across demanding applications including heavy-haul tanker and triple-trailer configurations. CNG/RNG efficiency favors highway-dominant duty cycles with predictable infrastructure access. RNG sourced from organic waste can achieve carbon-negative operations.
   
4. BEV technology is expanding beyond regional applications. Battery-electric trucks with 565 to 705+ kWh battery packs achieved 350 to 500+ mile daily operations, with an 875-mile validated single-day maximum on favorable terrain. Terrain sensitivity, charging infrastructure requirements, and payload constraints require corridor-specific evaluation before deployment.
   
5. Hydrogen fuel cells demonstrated operational characteristics but face significant barriers. Fuel cell trucks showed quick refueling and weight advantages over BEVs. However, infrastructure scarcity, high fuel costs, and energy pathway efficiency concerns present substantial challenges for commercial-scale deployment.
   
6. Real-world operational data complements specifications. Across all technologies, actual operational performance varied based on terrain, duty cycle, payload, and driver behavior. Specification sheets provide important baseline information; validated operational data helps fleet operators understand performance in specific applications and set realistic expectations.
   
7. Daily productivity matters as much as efficiency. Technology suitability depends not only on energy efficiency but on daily mileage capability — the ability to complete freight assignments within hours-of-service windows.
   
8. Infrastructure availability shapes deployment options. Charging and hydrogen refueling networks are developing unevenly across regions. Successful deployments require alignment between vehicle needs and infrastructure positioning along freight corridors.
   
9. Human factors influence outcomes across all technologies. Efficiency outcomes are shaped by driver training, performance incentives, maintenance discipline, and dispatch strategy. The highest-performing fleets in the Run demonstrated comprehensive operational optimization alongside technology selection.
   
10. Fleet strategy benefits from portfolio thinking. Many fleets will operate multiple powertrain technologies in the near- to mid-term, matching each to appropriate applications based on duty cycle, infrastructure access, and operational requirements.
    
11. Organizational culture influences technology success. Fleets that approach technology transitions with commitment and adaptability — from leadership to drivers and technicians — demonstrated stronger outcomes in Run on Less – Messy Middle.