Idling and Jump-Start Reduction Solution for C.R. England

Customer Challenge

C.R. England, one of the largest trucking companies in the U.S., faced persistent issues with excessive idling and costly jump-starts. Trucks often require auto-starts to recharge the starter and APU (auxiliary power unit) batteries, leading to increased fuel consumption, unnecessary engine wear, and costly downtime from battery-related failures.

Our customer asked: Can solar power maintain both the starter and APU batteries, reducing or eliminating idling and preventing jump-starts?

PowerFilm’s Solution

PowerFilm equipped a Freightliner Cascadia with a 440W solar system:

• Two 220W solar panels are engineered to precisely match the curves of the fairing, providing an OEM-quality fit that integrates seamlessly into the truck fairing.

• One IP67-rated charge controller, easily installed inside the cab, battery box or any convenient location.

Test Methodology

C.R. England designed a rigorous test to validate the system:

• Battery Setup: Removed eight AGM batteries and replaced them with lower-cost flooded batteries, reducing battery costs by half.

• Load Simulation: Installed a residential-style refrigerator, turned on all cabin lights, ran a radio, television, gaming system, and bunk fan. A microwave and a heater were also used intermittently to further stress the system.

• Test Conditions: Both panels were installed on trucks parked on the fleet’s property and were exposed to the same sunlight and weather conditions.

• Competitors Panel Performance (500W System): The competitor’s system failed after five days (~120 hours) when the truck had to idle to recharge the eight depleted batteries.

• PowerFilm Panel Performance (440W System): Ran continuously for one month (~800 hours) with zero idling. Throughout the test, batteries were never fully depleted, and the electrical loads remained operational.

• Weather Conditions: During the test, the trucks experienced a mix of sunny and cloudy days, along with day/night temperature swings, demonstrating real-world reliability under variable conditions.

Test Results

• Zero idling was required during the test period for the PowerFilm 440W system, and the truck never auto-started.

• The PowerFilm 440W system kept all eight flooded batteries charged across a month of heavy use.

• The competitor’s 500W system failed in less than a week under the same conditions.

• Even under variable weather conditions, the PowerFilm 440W system delivered consistent charging, with measurable output on cloudy days.

Key Benefits for Fleets

• Reliability: Maintains both starter and APU batteries without idling.

• Battery Life Extension: Reduced depth of discharge enables the use of lower-cost flooded batteries instead of AGM batteries, saving over $1,000 per truck in battery costs.

• Downtime Prevention: Near elimination of jump-starts means higher uptime.

• Fuel Savings: Eliminates unnecessary idling, significantly cutting fuel consumption.

• All-Weather Confidence: Continued performance under sunny and cloudy conditions.

Testimonial

"At C.R. England, we faced frequent dead batteries and high jumpstart costs on our tractors and trailers. Derek Durrant from Premier Truck Group introduced us to PowerFilm Solar’s panels. We tested eleven panels, including a 440W model for a tractor with an electric EPU. After three months, jumpstarts dropped to zero on test units, with panels maintaining a strong charge even after weeks of inactivity. When we experienced a minor issue, PowerFilm Solar quickly resolved it and improved their product. We’re very satisfied with the results and plan to continue using their panels."

-Aaron Durant, Director of Maintenance, C.R. England, Inc.

Conclusion

C.R. England’s month-long field test proved that PowerFilm’s 440W solar system keeps both starter and APU batteries charged without idling. Compared to a competitor’s 500W system, which failed in less than a week, PowerFilm delivered sustained, reliable power for a month.

The result: lower fuel costs, reduced maintenance, extended battery life, and a clear ROI. With savings from reduced idling and the ability to switch from AGM to flooded batteries, the system offers a rapid payback period, helping fleets see returns in as little as the first year of operation.*

*Exact ROI timeframe to be confirmed by the customer.