Colas Rail UK cuts fuel use and emissions with novel pick-up system

Colas Rail UK is seeing significant reductions in fuel consumption and carbon emissions thanks to a new fuel delivery system called FuelActive. The innovative pick-up pipe, which can be installed in any type of diesel machinery, is projected to save the company the equivalent of up to 365 tonnes of CO2 in 2024, with even greater reductions expected as it's rolled out to more equipment.

“When I first saw FuelActive, I immediately thought about the ideal fuel pick-up point, away from dirt and water at the bottom of the tank,” said Daniel Bird, maintenance manager, Rail Profile Treatment Fleet at Colas Rail UK. “It reduces maintenance, keeps filters clean, and extends the life of our machinery. Overall, it’s a fantastic invention.”

FuelActive works by using a floating pick-up mechanism instead of the traditional system that draws fuel from the bottom of the tank. This ensures only the cleanest fuel reaches the engine's injection system, resulting in a cleaner burn and lower emissions.

“Working with contaminated diesel is a major challenge in our industry,” Bird explained. “It's difficult to control fuel quality, but where it's delivered within the tank matters most.”

Trials conducted over six months on eight Colas Rail UK engines showed an average fuel saving of 4-7%. The company also observed increased engine reliability, with fewer injector problems and a fourfold increase in fuel filter lifespan.

Financial and operational support from Network Rail allowed Colas Rail UK to trial the system in its machinery fleet.  “We spend roughly £1.8 million annually on fuel, generating around 5,000 tonnes of CO2 equivalent,” said Alejandro Moreno, business development director at Colas Rail UK. “Anything that effectively reduces those figures is worth exploring, and FuelActive is proving its value.”