A newly published whitepaper from Dragonfly Energy, developed in collaboration with truck manufacturer PACCAR, analyzes how its lithium-powered idle-reduction solutions stack up against traditional diesel and AGM-based systems in terms of performance, reliability, and operational efficiency.
The findings were revealed last week at The Battery Show North America 2025 in Detroit, Michigan.
Titled Reducing Idle Time & Fuel Costs: Lithium Powered Solutions for Commercial Fleets, the whitepaper includes real-world fleet trial data and Environmental Chamber Testing from the PACCAR Technical Center, claiming it confirms the technology's performance in extreme operating conditions. Dragonfly developed its own lithium-powered idle reduction system, called the Battle Born DualFlow Power Pack.
The paper points out that "For fleets not yet ready to adopt full electric APUs, especially those operating in regions with limited seasonal A/C demand... [Dragonfly's DualFlow Power Pack] offers as a cost-effective, drop-in anti-idling solution."
How the DualFlow Power Pack works
Dragonfly explains the power pack system is designed for easy installation under the sleeper cab bunk, whether as a retrofit or factory option. It powers non-A/C hotel loads like cabin lights, electronics, CPAP machines, and other accessories. It also helps maintain chassis starting batteries, reducing the need for jump starts and easing strain on the truck's electrical system.
Equipping trucks like the PACCAR Peterbilt 579 with high-capacity hybrid batteries—such as Dragonfly's Battle Born models—allows drivers to power sleeper amenities like refrigerators, air conditioning, and heaters for hours without relying on idling diesel engines. This results in cleaner and quieter rest periods and reduced fuel costs, with the added benefit of a better night's sleep free from engine noise.
[Related: Check out Kenworth's T880E, T680E BEV trucks with PACCAR's ePowertrain]
Equally important, using Dragonfly's power pack is a way to avoid (without having to have to purchase a pricey battery-electric rig with now non-existent federal subsidies) diesel exhaust particulate matter, nitrogen oxides, and various airborne toxins, many of which are recognized as known carcinogens.
Key findings
The whitepaper details key outcomes for fleets, including:
- Fuel and cost savings: Significant reductions in fuel consumption and idle hours compared to diesel APUs and AGM systems.
- Driver comfort and safety: Reliable power for full 10-hour rest periods without disruptive engine restarts.
- Fleet reliability: Lower maintenance costs and extended engine life by reducing unnecessary idle wear.
- Proven results: Performance validated through testing at the PACCAR Technical Center and confirmed in commercial fleet trials.
More specifically, fleets using the Battle Born All-Electric APU system, the paper claims, have seen annual savings of up to $6,500 per vehicle, with total savings over eight years surpassing $60,000 per truck compared to operating without an anti-idling solution.
"We believe idle reduction remains one of the most immediate and cost-effective ways fleets can reduce fuel consumption and emissions while improving driver comfort. But just as important, the industry is increasingly focused on operational efficiency and maximizing asset utilization," said Wade Seaburg, chief commercial officer at Dragonfly Energy. "We believe our collaboration with PACCAR not only validates the performance of our LiFePOâ‚„-powered solutions, but also highlights how they help fleets maximize uptime, extend equipment life and get more out of their assets."
