Cut Your Fuel Costs by 10%:

Cut your FUEL COSTS by 10%!  Ceramic Coatings can Help Fuel Efficiency
Powerkote's affiliates in the USA just recently discovered that ceramic coatings can save fuel! Having successfully coated the exhaust systems of a number of large transport trucks, tests were conducted on the drivers usual routes yielding astonishing results of between 10 and 20% less fuel consumption.


Huge fuel savings found in the U.S.A. after using ceramic coatings

Transport Truck Exhaust System Coating                                                                                                             Project 7001

Monitoring of fuel consumption is ongoing. The overall improvement in fuel economy from Mar 5 up to May 24 2007 is 11.0%. This covers 36,700 miles of hauling loads ranging from 8,000 to 40,700 lbs

Exhaust System Coating                                                                                                                                          Project 7001

5 August 2008

The latest test of the ceramic coated exhaust and turbo system saw 20% improvement on a Cummins Diesel. A Class 8 flat bed with a fork lift attached to the back deck for deliveries. Several empty runs were made over the same route with two different drivers. One being the regular driver and the other the owner to verify the results. Both saw fuel consumption drop from 18 gallons to 14 gallons for the route. On other loaded runs, the savings has still been 20%.This truck was monitored before coating and after, for accurate comparison. All were class 8 Turbo Diesels.

To date we have:
Volvo:                              10% plus consistently over 40,000 miles
Older Detroit Diesel:      over 9% constant
Cummins:                         over 20% constant

Note : Some gains will be based on route and load as well as the condition of the
Exhaust Manifold Coating Improves Diesel Engine Fuel Economy

Thin film ceramic coatings (TFCC) on diesel engine exhaust components reduce

heat loss from the exhaust gas. The result is more available horsepower and

torque that can be used to reduce fuel consumption. 

Fuel Economy

Monitoring the fuel consumption of a 12L diesel transport truck engine for

15,000 mi each before and after applying TFCC shows an average 10.3% increase in fuel economy over a wide range of load weights. The improvement is statistically significant at the 99.9% confidence level.

HP - Torque

Chassis dynamometer testing shows a 7% increase in the peak rear wheel (RW) hp and the RW torque in the cruise rpm range (see graph). 

The Owner/Operator commented that on climbs through mountains he could use a gear 1 to ˝ higher after coating and could go higher up the mountain before needing to down shift. Also the pulling of the heaviest loads is better than expected (noticeably easier) after the coating.






















Manifold Surface Temperature

The TFCC manifold and turbo housing surface temperature averages 2320C (4500F) lower. The TFCC surfaces are below the ignition temperature of hydraulic fluid, 2070C (4050F), reducing the risk of fire if a hydraulic leak occurs.

Underhood temperatures will also be reduced significantly which will increase the life of heat sensitive components.
Higher exhaust gas temperature burn off more particulates, thereby reducing emissions and pollution.


Typical Mileage Data

TFCC Coated Components Installed


















Powerkote Improves Fuel and Power!

Tests carried out in South Africa by Malcom Kinsey, a member of the Guild of Automotive Journalists produced some outstanding results. Three stop standard Toyotas were coated. The pistons, cylinder heads, intake and exhaust manifolds were coated with Powerkote ceramic coatings, these were the results:

                                                                   0-100                                        Top Speed                                      1/100km

Toyota Tazz 1300

Standard                                                     12.8 sec                                      168 km/h                                          9.3

Coated                                                        11.2                                               177                                                 7.9

Toyota Corolla 1.6                                 

Standard                                                     10.3                                               185                                                 9.0

Coated                                                        9.7                                                190                                                 8.1

Toyota Corolla 1.8                               

Standard                                                      9.9                                                188                                                 9.4

Coated                                                         9.1                                                194                                                 8.0

Coating Exhaust Manifolds 

Exhaust manifolds can either be a cast iron, factory-type manifold or a tube steel header typically used in performance applications, though they are becoming very common in OEM applications. 
There are a variety of reasons for coating an exhaust manifold header.

#1 Corrosion protection. The manifold will live longer as well as look nicer. The coating being a even layer allows the heat to move faster and more evenly over the metal, this elevates cracking and hotspots.

#2 The coating is a thermal barrier, thus keeping heat within the manifold or header.

There are a number of benefits for this. First, by keeping heat within the manifold, you're going to accelerate the exhaust gas velocity which reduces back pressure and reduces fuel contamination due to reversion. This is a performance benefit which applies to both petrol and diesel engines. Coating the exhaust turbo housing along with the exhaust manifold spools up the turbo faster and reduces lag, this combination increases power and in turn reduces fuel consumption.

Second, you'll reduce the surface temperature of the manifold. If there is a component close to it, it will not see as much heat as it would with an uncoated manifold. In addition, not as much heat will be radiated under the hood or into the engine compartment. This reduces the under hood temperature which, again, reduces the temperature of surrounding parts, such as, alternators and starters. It also reduces the amount of heat that can be drawn in through the carburetor, which is a secondary performance benefit. There are a variety of coatings that can be used on exhaust manifolds or headers.