Railroads across North America are under increasing pressure to reduce emissions, improve fuel efficiency, and meet sustainability targets. One of the most persistent barriers to these goals? Locomotive idling.
Excessive idling leads to unnecessary fuel consumption, increased maintenance, and harmful greenhouse gas emissions. This is where KickStart, ZTR’s supercapacitor-based starting assist solution, plays a critical role not just in ensuring reliable engine starts, but in enabling railroads to confidently reduce idling time without compromising start performance.
The Idling Problem: Why Locomotives Stay Running
Railroads often leave locomotives idling for one key reason: to prevent battery drain and ensure reliable engine restarts. This practice, while operationally convenient, results in:
- Thousands of gallons of wasted fuel per locomotive per year
- Increased greenhouse gas (GHG) emissions
- Accelerated engine wear
- Higher maintenance costs
The underlying problem is battery reliability, especially in cold temperatures or after long periods of inactivity. When batteries are weak or unstable, railroads are forced to choose between idling or risking a failed restart.
Battery Failures: The Hidden Culprit
Dead-won't-start (DWS) events represent one of the most disruptive failures in locomotive operations. On average, each locomotive experiences a DWS failure once every three years, typically caused by battery voltage drops during engine cranking.
Here's what happens during a failed restart: High current draw from engine cranking causes weakened battery voltage to drop below the minimum threshold required to maintain onboard electronics. Once voltage falls below this dropout level, the locomotive's control systems cycle and cranking ceases, resulting in a failed start.
Research shows that 20% of locomotive idle time stems from battery-related issues, with half of those problems directly attributable to weakened batteries. This means 10% of all locomotive idling could be eliminated by addressing battery performance challenges.
How KickStart Solves the Problem
Supercapacitor-based starting assist systems like KickStart address the root cause of excessive idling by providing reliable cranking power regardless of battery condition. This advanced technology uses supercapacitors to deliver immediate, high-power support during engine startup.
The system works by connecting supercapacitors in parallel with locomotive batteries just before cranking begins. During the critical startup phase, supercapacitors provide the peak current needed for successful engine starts while reducing strain on the battery system.
Key advantages include:
- Reliable starts in all conditions: Supercapacitors perform consistently across temperature ranges and battery states
- Battery preservation: Reduced cycling and current draw extends battery life significantly
- Instant availability: No warm-up time or complex preparation required
After a successful start, the supercapacitor module rapidly recharges from the auxiliary generator, typically within minutes. When the engine shuts down, the supercapacitor disconnects from locomotive circuits to preserve its charge for the next start cycle.
Sustainability Gains: Measurable and Meaningful
The environmental impact of reducing locomotive idling extends far beyond fuel savings. When locomotives can shut down reliably, the sustainability gains are both immediate and substantial.
Fuel Consumption Reduction
Field data from KickStart installations demonstrates significant fuel savings through reduced idle time. On SD40-2 locomotives, the technology provided an additional 18 hours of shutdown time per month per unit—a 50% reduction in idle time caused by battery charging requirements.
This translates to over 1,080 gallons of fuel saved per locomotive annually, representing roughly $4,320 in cost savings at current diesel prices. More importantly, this reduction eliminates unnecessary fuel consumption without compromising operational reliability.
Emissions Impact
The emissions benefits are equally impressive. Each gallon of diesel fuel consumed produces approximately 10,180 grams of CO2. By saving 1,080 gallons annually per locomotive, supercapacitor starting technology prevents 10.9 tonnes of CO2 emissions per unit each year.
Beyond CO2, these reductions represent tangible decreases in air quality contaminants including particulate matter, nitrogen oxides, and carbon monoxide—pollutants that directly impact public health.
Extended Battery Life
Supercapacitor starting assist extends locomotive battery life from the typical 2 years to 4-5 years by reducing deep discharge cycles and battery stress. This improvement reduces environmental impact from battery production and disposal while cutting maintenance costs.
Case studies show an 85% reduction in battery voltage restarts, significantly decreasing the cycling that leads to premature battery failure. Additionally, crank time on restarts is reduced by 25%, further minimizing stress on both batteries and starting systems.
System Integration and Data Visibility
Modern supercapacitor starting systems don't operate in isolation. When integrated with automatic engine stop-start (AESS) systems and remote management platforms, they become part of a comprehensive efficiency ecosystem.
AESS systems like SmartStart automatically shut down locomotives under predetermined conditions to reduce idle time and conserve fuel. However, these systems require sufficient battery state-of-charge before initiating shutdown. Supercapacitor starting assist eliminates this constraint, allowing more aggressive idle reduction without restart risk.
Remote monitoring platforms like Vision from ZTR provide the data visibility needed to monitor idle reduction, fuel usage, and starting events across the entire fleet. This insight enables continuous optimization of sustainability strategies and demonstrates measurable progress toward environmental goals.
Building a Greener Rail Network, One Start at a Time
The transition to sustainable rail operations doesn't require revolutionary changes to existing infrastructure. Sometimes, the most impactful improvements come from addressing fundamental operational challenges with advanced technology.
Supercapacitor starting assist systems demonstrate this principle perfectly. By addressing the root cause of excessive idling, battery-related starting failures, this technology empowers railroads to take control of their energy usage, reduce costs, and move toward a greener future.
The data speaks for itself: reduced fuel consumption, lower emissions, extended battery life, and improved reliability. For railroads committed to environmental stewardship and operational excellence, supercapacitor starting technology offers a proven path forward.
Ready to transform your fleet's sustainability performance? Learn more about KickStart and discover how advanced cranking technology can drive your environmental goals while delivering measurable financial returns.