SER validates “hydrogen-on-demand” with up to 25% fuel saving in Ultimate Cell® trial
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After a rigorous nine-month evaluation via OEM telematics, Stevens Equipment Rental is now offering Ultimate Cell® technology to help customers reduce fuel spend and CO2 emissions on major earthmoving projects.
The results are drawn from controlled, real-world trials and reflect performance under specific operating conditions. As with all heavy equipment, fuel efficiency outcomes will vary depending on factors such as machine type, application, terrain, operator behaviour, and duty cycle. However, the trial demonstrates the consistent potential for measurable fuel and emissions improvements when deployed correctly.
The evaluation focused on two heavy-duty assets: a 35-tonne excavator and an 18-tonne loading shovel from the SER fleet. Using the OEM telematics, SER and Ultimate Cell tracked daily fuel consumption for three months to establish a baseline, followed by six months of active monitoring post-installation.
Valuable efficiency gains
During the six-month active monitoring, the excavator showed consistent fuel savings. Based on annual operating hours of 2,000, SER estimates that thousands of litres of fuel and over 10 tonnes of CO2 could be saved, offering a strong return on investment for users in addition to emissions reductions. In peak conditions, savings of over 25% were recorded.
The loading shovel trial also showed an overall reduction during the six-month period, with savings of over 10% in some cases compared with a traditional machine operating under the same conditions.
Operators noted stronger torque, smoother operation, and quieter engine behaviour across both machines.
“We are taking a pragmatic approach to decarbonisation,” said Mark Need, sales manager for Scotland and the north of England at SER. “While the industry waits for large-scale electric or full-hydrogen solutions to become commercially viable for heavy earthmoving – especially in remote locations – this trial proves our customers can use Ultimate Cell® to reduce their impact today. It strengthens sustainability proposals for contractors tendering for major infrastructure projects.”
An Ultimate Cell ® unit fitted to a Volvo L120H wheel loader in the SER fleet.
How the technology works
The non-invasive retrofit system draws a low amperage from the engine battery to split an electrolyte fluid into hydrogen and oxygen, which are then injected into the engine air intake in controlled, small amounts.
These gases act as a catalyst to accelerate combustion for a more complete fuel burn that enables the engine to generate higher torque from the same volume of diesel with significantly less soot.
Over time, the high-temperature chemical reaction of the hydrogen helps to gradually strip existing carbon deposits from the engine, which may also contribute to a reduction in carbon build-up.
The system requires zero additional operator training and can only be seen when the engine cover is opened. The only maintenance required is electrolyte replacement, typically required at extended operating intervals and only takes minutes. The fuel cells can be easily removed to return equipment to the original OEM condition or transferred to other machines.
The Triple Ultimate Cell ® unit (three cells in total) fitted to a Volvo EC350E excavator in the SER fleet.
From trial to fleet offering
Satisfied with both the performance data and ease of maintenance, SER has now integrated the technology into its commercial offering. Customers can specify Ultimate Cell® installation on machines hired from the SER fleet to meet project-specific ESG requirements.
Gareth Eeson, managing director of Ultimate Cell UK, said: “The SER team went into the trial with an open mind and a genuine appetite for innovation. They worked supportively with us to optimise the set-up with fortnightly check-ins at the start and a commitment to double-checking every result. SER can now confidently offer a solution that is largely invisible to the operator, but highly visible on the balance sheet and the sustainability report.
“By combining structured data analysis with real operational feedback, we’ve demonstrated that combustion optimisation can deliver measurable fuel and emissions reductions today, without waiting for future infrastructure or fleet replacement.”
Fuel savings were validated against real-world duty cycles using OEM telematics, with results normalised to account for variations in workload, idle time, and operating conditions.
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