Why fleet remapping makes more sense than single-machine remapping
The cost structure of plant remapping includes a fixed component — site attendance, travel, setup — and a variable component — the actual remap work per machine. When multiple machines are remapped on the same site visit, the fixed cost is shared across the fleet, reducing the per-machine cost.
The fuel saving, by contrast, scales linearly — each machine saves independently. A fleet of 8 ADTs saves 8x the fuel of one. The economics of fleet remapping are therefore significantly better than single-machine remapping, and improve further with fleet size.
For quarry operators, civil engineering contractors, and plant hire companies with large fleets, a fleet remapping programme is one of the highest-return investments available.
How we plan a fleet remap site visit
Before the visit: We compile a machine list — make, model, approximate hours, and any known Adblue or DPF issues for each machine. We confirm ECU access capability for each model and prepare the appropriate equipment. For less common machines, we research access methods in advance.
On the day: We work through the fleet in a planned sequence, typically starting with the machine most likely to have issues (allowing more time if needed) and working through to the most straightforward. Each machine gets the full diagnostic assessment before the remap — we do not cut corners on the fleet just because there are more machines to do.
Post-visit: We provide a summary of the work done on each machine, including the calibration applied, any fault codes found and addressed, and fuel saving projections for the fleet.
Fleet ROI: the numbers scale well
Single machine: 20-tonne excavator saving 10% on 11 litres/hour, 2,000 hours/year = £2,420 annual saving.
Fleet of 6 machines (same type): 6 × £2,420 = £14,520 annual saving. With fleet pricing reducing the per-machine remap cost, the payback for the whole fleet is typically 2–4 months.
Quarry fleet: 8 × 30-tonne ADT saving 12% on 20 litres/hour, 2,500 hours/year = £6,600 per machine = £52,800 fleet annual fuel saving.
The fleet ROI calculation is always the most compelling. For a business that runs 10 or more plant machines, fleet remapping should be a routine line in the plant management programme rather than a reactive measure.
What machines to include in a fleet programme
Include all diesel-engined plant that is owned outright and in regular use. Prioritise:
High-utilisation machines first: Machines running the most hours per year generate the largest absolute saving and pay back fastest. ADTs on continuous haul cycles and excavators in all-day dig-and-dump are the highest priority.
Machines with Adblue or DPF issues: Combine the remap with resolution of existing emissions system faults — one visit, multiple improvements, reduced future downtime.
Larger machines: The fuel saving scales with consumption. A 30-tonne ADT saves more in absolute terms than a 10-tonne excavator at the same percentage. Larger machines should be prioritised on pure ROI grounds.
Machines that still have older, unremapped calibrations: Some fleet managers have remapped individual machines over time but have not done the whole fleet. A fleet programme catches the remaining machines.
Fleet management considerations
Record keeping: We provide documentation for each machine remapped. Maintain this alongside your plant service records. If a machine is sold, the remap documentation should accompany it.
Returning machines to factory: The original ECU calibration is backed up before every remap. If a machine is returned to a lessor or sold to a buyer who requires factory spec, we can restore the original calibration.
New machine additions: As new machines are added to the fleet, bring them into the remapping programme once they are outside the manufacturer warranty period.
Phased programmes: For large fleets, a phased approach — remapping the highest-priority machines first, then working through the fleet — allows the fuel savings from Phase 1 to contribute to funding subsequent phases.
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Plan a fleet remap programme
Send us your plant list — makes, models, hours — and we'll put together a fleet programme and price.
Common Questions
What fleet size qualifies for fleet pricing?
Fleet pricing applies from 3 machines on the same site visit. The per-machine rate reduces further with higher numbers. Contact us with your fleet list and location for a specific fleet price.
Can you remap different machine types on the same fleet visit?
Yes — a fleet visit can include excavators, ADTs, loaders, telehandlers, and other plant types. We prepare for the full machine mix in advance and arrive with the appropriate equipment for each type.
How long does a fleet visit take?
Plan approximately 2–3 hours per machine for medium and large plant, less for compact machines. A fleet of 6 ADTs might take a full day; a mixed fleet of smaller machines may be similar. We plan the visit timing when you confirm the fleet list.
Do you travel to remote sites for fleet remapping?
Yes — we attend sites across the UK including remote quarry locations. Travel cost is factored into the fleet price. For large fleets, travel cost is a small proportion of the total.
Can you provide a written fuel saving projection for each machine in the fleet for business case approval?
Yes — we provide written fuel saving projections for each machine in the fleet based on the machine type, consumption data, and annual hours you provide. This is useful for internal approval processes.