Stopping Distances vs. Fuel Economy: The Hybrid Truck Dilemma for Fleet Operators

Trade-Offs Between Fuel Economy and Safety in Fleet Operations

Many fleets today seek ways to increase their fuel economy. They may use various methods to do so, including switching to hybrid or electric trucks. While these trucks bring advances in fuel economy, these changes may impact safety.

A 2025 report from the Massachusetts Institute of Technology (MIT) Motion Initiative found that the heavier the vehicle, the less effective its braking capacity. Also, electric vehicles accelerate faster but lack the braking performance to match the increase in acceleration.

This increase in stopping distance could at least partially come from the large-scale adoption of low rolling resistance (LRR) tires. These tires are specially designed to increase fuel efficiency, lower costs, and decrease emissions, but they may also increase braking distances.

Fleet operators should note this finding, given the current trend among fleet management of fuel economy being king. Fleet operators may have to accept that, at a certain point, the interests of drivers and public safety need to be considered when selecting tires for their fleet.

Here’s what fleet operators should look for when selecting tires that offer the best of both worlds in terms of improving fuel economy without sacrificing stopping distances or tire durability.

Consider Contact and Tread Depth for Hybrid Vehicle Tires

A key factor in determining how well low rolling resistance tires actually grip the road — and therefore how far they contribute to shortening stopping distances — is how their reduced rolling resistance is achieved in the first place.

When low rolling resistance tires were first developed in the 1990s, reduced rolling resistance was primarily achieved by either narrowing the tire tread (the part of the tire that came into direct contact with the road) or reducing the tread depth (the depth of the grooves in the tire’s tread). Both these modifications directly offset the amount of grip and traction that a tire offers a vehicle, meaning that at a certain point of fuel efficiency, a tire simply will not be safe to use.

Mike Skoropad, Head Technician at United Tires, says: “For heavy-duty vehicles, as those typically driven in commercial fleets, you do not want to sacrifice tire width for a potentially improved fuel economy. That width is needed to ensure proper grip at high, constant speeds. Ensure that low rolling resistance tires are not narrower than the required width in your vehicle owner’s manual.”

Mike added, “Also, ask your supplier about the tread depth of your low rolling resistance tires. You want tires that start at around 8/32 inches of tread depth. Anything under 4/32 of an inch begins to compromise safety, so you want several years’ worth of wear before you get to that point.”

What You Should Want in Low Rolling Resistance Tires

Low rolling resistance tires that do not sacrifice stopping distances (or at least keep this sacrifice to a minimum) achieve their reduced rolling resistance through the materials used in the tire rather than the shape and structure of the tire.

You, therefore, want low rolling resistance tires to have a similar shape and structure (including tread structure) as the tires that come as standard on your vehicle. The difference between the tires should be primarily in the compounds that they are made of.

Short of learning the ins and outs of tire engineering, fleet operators should look specifically at these factors when choosing low rolling resistance tires:

• Labeling: Look at how the tires are labeled. Tires are evaluated out of 100 on three metrics: fuel efficiency, ability to grip the road, and durability. You want to opt for a tire that has a nice balance of all three characteristics.
• Sidewall: Where possible, opt for a tire with a larger sidewall. The materials that lower rolling resistance can make sidewalls less elastic, and a higher sidewall can accommodate this loss.
• Expense: Accept that the compounds used in safer, low-rolling resistance tires are expensive and that this price will have to be passed on to the customer. Cheaper options tend to sacrifice grip and traction for fuel economy. Budget this out when choosing what tires to equip your fleet with.

If budgets do not stretch far enough to kit out your fleet with state-of-the-art tires, then pick your sacrifice based on your fleet’s needs. If your fleet regularly travels on poorer-quality roads, then you do not want to sacrifice durability. Conversely, for long-haul vehicles, striking a balance between fuel efficiency and grip should be given the highest priority.

Alternative Ways to Enhance Fleet Fuel Efficiency While Managing Safety

Hybrid trucks can enhance fuel efficiency while maintaining safety as long as they have the right tires. Whether you switch to hybrid trucks or continue using internal combustion engine (ICE) fleets, there are a few other things you can do to improve fuel efficiency without decreasing safety.

Data Collection

Telematics data can tell fleet managers about how their fleets run. As you collect data, you may see differences between trucks and drivers. These details can help you make changes. Over time, you can see the impacts of the tweaks you make and continue adjusting.

Vehicle Selection and Maintenance

Before you choose new trucks for your fleet, discuss fuel efficiency features, such as aerodynamics and tire and trailer gap features. Ensure any fuel efficiency features still maintain effective safety. After purchasing, maintain fuel efficiency through regular service. Properly maintained vehicles perform better in every area, including fuel economy.

Driver Behavior

A truck’s fuel efficiency often varies based on the driver. Fleet management for fuel consumption may involve training programs to encourage more fuel-efficient behavior, such as:

• Limiting jackrabbit starts
• Maintaining proper following distances
• Anticipating traffic lights
• Limiting maximum vehicle speeds

Idling Reduction

Idling quickly consumes fuel. It may occur for various reasons, such as when driving in congested areas. Fleet operators can reduce this cause of idling through route planning to avoid driving through busy areas at peak hours. Drivers may also idle the vehicle overnight. Education regarding the effects of long-term idling may help operators think twice before idling their trucks for long periods.

How Do Electric Vehicles Fit Into the Picture?

The main way that electric and hybrid vehicles affect tires compared to their fuel-powered counterparts is that their additional weight means that tires will wear faster and be subject to more pressure.

This means that operators with electric vehicles in their fleets should look for tires that score particularly well in terms of durability. Often, low rolling resistance tires score badly on this measurement, as the materials that reduce resistance also weaken the tire’s sidewall. The more fleets adopt electric vehicles, the better this technology will become.

Manage Risks With Insurance Solutions

Fleet owners should accept that improving their fleet’s fuel economy by lowering the rolling resistance of the tires will inevitably involve a loss of tire durability or traction. Other interventions like telematics or driver behavior changes can help enhance efficiency while managing safety.

You can also manage this risk with reliable and comprehensive commercial trucking insurance solutions. XINSURANCE specializes in identifying effective commercial trucking insurance solutions and can provide options to fit your needs. Fill out our online form to request a quote.

Authored by Rick J. Lindsey, President, Chairman, and CEO of XINSURANCE

Rick J. Lindsey hails from Salt Lake City, Utah. He began working in the mailroom of his father’s Salt Lake City insurance firm, getting his introduction to the business that became his lifelong career. Rick J. Lindsey quickly rose through the ranks while working in nearly every imaginable insurance industry job. As an entrepreneur, specialty lines underwriter, claims specialist, risk manager, and a licensed surplus lines broker, Rick J. Lindsey is highly skilled in all levels of leadership and execution. As he progressed on his career path, Rick J. Lindsey discovered an urgent need for insurers willing to write policies for high-risk individuals and businesses. He was frequently frustrated that he could not provide the liability protection these entities desperately needed to safeguard their assets. He also formed the belief that insurance companies acted too quickly to settle frivolous claims. Rick J. Lindsey decided to try a different approach. He started an insurance company and became the newly formed entity’s CEO. This opportunity has enabled Rick J. Lindsey to fill a void in the market and provide a valuable service to businesses, individuals, and insurance agents who write high-risk business. XINSURANCE also specializes in helping individuals and businesses who live a lifestyle or participate in activities that make them difficult for traditional carriers to insure. If you’ve been denied, non-renewed, or canceled coverage, don’t give up quite yet. Chances are XINSURANCE can help.