Therma-Start Off-Highway

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Off Highway Idle Reduction

  • Reduce idle time by 80%
  • Reduce fuel consumption by 80%
  • Reduce carbon emissions by 80%
  • Constantly monitors all critical systems

WHAT IS THERMA-START™ FOR OFF HIGHWAY EQUIPMENT?

Therma-Start™ is a non-invasive retrofit start-stop system that easily installs on diesel-powered vehicles and equipment. The system eliminates unnecessary idling, saves on fuel consumption, extends oil change intervals and saves on maintenance costs. The latest in Start/Stop technology, Therma-Start™ is the definitive way to drastically reduce and manage operating costs while achieving major emissions reductions.

ThermaStart™ acts as an auto start/stop control system that does not intrude into the OEM engine data system but rather operates as a Virtual Key Switch, paralleling the existing ignition key switch and duplicating its functions. ThermaStart™ monitors battery condition, ambient temperature, engine block temperature and air pressure to make decisions based on programmed parameters to either start-up or shut down an engine. Idle reduction results are verified by on-board data logging.

ThermaStart™ Documentation

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HOW IT WORKS

Therma-Start™ is constantly monitoring the engine block temperature, battery voltage, and for air-start machines the tank air pressure. When the block temperature drops to a pre-set point, the engine automatically starts. Therma-Start™ is programmed to go through a safety signaling delay before initiating each start-up cycle. When the engine block resumes optimal temperature, Therma-Start™ signals the engine to automatically shut down. Therma-Start™ also continuously monitors battery condition so a start-up can be initiated if a battery is losing charge due to cold weather extremes. Operators can confidently walk away from their machines knowing that Therma-Start™ is in charge!

FEATURES & BENEFITS

Using a 789C CAT Haul truck for example the following savings were realized once ThermaStart™ was installed:

  • Reduced idle time by 80% – from 12 hours down to 2.4 hours per shift
  • Reduced fuel consumption by 80% – from 149 Gals (564 L) down to 30 Gals (114 L) per shift
  • Reduced carbon emissions by 80% – from 2,866 lbs (1,300 kg’s) of Co2 down to 573 lbs (260 kg’s) of Co2 per shift

PAYBACK PERIOD

In this example, from fuel savings alone payback is accomplished in less than 1 month!

When you also factor in significantly extended maintenance intervals (ie. differential rebuild) along with greatly reduced wear and tear your payback savings escalate dramatically.

Therma-Start – Business Case

Therma-Start™ (Off-Highway) Cost-Benefit Analysis (CAT)

Installed On: Cat 789 Haul Truck:

Application: 12hr operating / 12 hr idling
Average Price :
$7,500
Install Cost:
$5,000

Installed Cost : $12,500

 

Life Cycle Operating Costs without ThermaStart:

Cold weather operating months (Nov-Mar) = 5 months x 30 days x 12hrs/day = 1,800 idle hours/year x $430/hour = a Life Cycle Operating Cost of $774,000 (includes fuel, maintenance and depreciation)

 

Life Cycle Operating Costs with ThermaStart:

80% reduction in idling hours = 360 idle hours/year x $430/hour = a Life Cycle Operating Cost of $155,000 (includes fuel, maintenance and depreciation)

 Annual Savings with Therma-Start = $619,000

Payback period: 7.4 days

Installed On: Cat 966 Loader:

Application: 12hr operating / 12 hr idling
Average Price :
$7,500
Install Cost:
$3,500

Installed Cost : $11,000

 

Life Cycle Operating Costs without ThermaStart:

Cold weather operating months (Nov-Mar) = 5 months x 30 days x 12hrs/day = 1,800 idle hours/year x $230/hour = a Life Cycle Operating Cost of $414,000 (includes fuel, maintenance and depreciation)

 

Life Cycle Operating Costs with ThermaStart:

80% reduction in idling hours = 360 idle hours/year x $230/hour = a Life Cycle Operating Cost of $83,000 (includes fuel, maintenance and depreciation)

Annual Savings with Therma-Start = $331,000

Payback period: 12.1 days

Therma-Start™ (Off-Highway) Cost-Benefit Analysis (Komatsu)

Installed On: Komatsu 930E Haul Truck:

Application: 12hr operating / 12 hr idling
Average Price :
$7,500
Install Cost:
$5,000

Installed Cost : $12,500

 

Life Cycle Operating Costs without ThermaStart:

Cold weather operating months (Nov-Mar) = 5 months x 30 days x 12hrs/day = 1,800 idle hours/year x $430/hour = a Life Cycle Operating Cost of $774,000 (includes fuel, maintenance and depreciation)

 

Life Cycle Operating Costs with ThermaStart:

80% reduction in idling hours = 360 idle hours/year x $430/hour = a Life Cycle Operating Cost of $155,000 (includes fuel, maintenance and depreciation)

Annual Savings with Therma-Start = $619,000

Payback period: 7.4 days

Installed On: Komatsu WA500 Loader:

Application: 12hr operating / 12 hr idling
Average Price :
$7,500
Install Cost:
$3,500

Installed Cost : $11,000

 

Life Cycle Operating Costs without ThermaStart:

Cold weather operating months (Nov-Mar) = 5 months x 30 days x 12hrs/day = 1,800 idle hours/year x $230/hour = a Life Cycle Operating Cost of $414,000 (includes fuel, maintenance and depreciation)

 

Life Cycle Operating Costs with ThermaStart:

80% reduction in idling hours = 360 idle hours/year x $230/hour = a Life Cycle Operating Cost of $83,000 (includes fuel, maintenance and depreciation)

Annual Savings with Therma-Start = $331,000

Payback period: 12.1 days