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XL Hybrids vehicles have gone 42 million miles, saving 788,000 gallons of fuel.
April 20, 2017

XL Hybrids sells electric drive systems to companies including Coca-Cola, which showed 20 percent reduction in fuel use in fleet

The saying about solar power is that it pays for itself, but not in your lifetime: The same thing could be said about hybrid vehicles. Yes, they run cheaper and they’re better for the environment, but the initial investment can be daunting.

If that’s true for individual consumers, consider the plight of fleet managers who oversee hundreds or thousands of vehicles. 

But a company nurtured by Arizona State University has hit upon a solution, offering systems to convert new or existing fleets to hybrid vehicles.

It’s a technology that has been snapped up by Coca-Cola, the city of Boston, the Seattle Fire Department, ThyssenKrupp Elevator Americas and AmeriPride Services.

XL Hybrids sells electric drive systems that use regenerative braking to cut back on fuel use. An electric motor helps slow the vehicle during braking, which charges the hybrid battery. When the driver accelerates, the hybrid battery releases the stored energy to the electric motor, helping to propel the vehicle.

To date, XL Hybrids converted vehicles have driven more than 42 million customer miles. That’s more than 87 round-trip journeys to the moon. XL converted hybrids have saved almost 788,000 gallons of fuel. That’s 49,250 fillups for an average SUV. They have kept more than 7,000 tons of carbon dioxide out of the air, and saved 6,300 hours of driver productivity by being on the road longer and not returning for gas topoffs. That’s more than 157 work weeks, or roughly a year’s work of three employees.

Companies attracted to the technology tend to have put 30,000 to 40,000 miles per year on vehicles they keep for about a decade. Add that up, and it’s the equivalent of about 14 trips from Los Angeles to New York. They can cut fuel bills for urban driving by 20 percent and CO2 emissions by the same percentage. 

“It can definitely turn into a very meaningful number when they have tens of thousands of vehicles in the fleet,” said XL Hybrids chief executive officer and founder Tod Hynes.

The XL3 Hybrid Electric Drive System installs in a day, underneath the vehicle body.

“The hybrid system is easy to deploy and easy to rollout,” Hynes said. “We tried to fit into the existing infrastructures.”

Coca-Cola converted 280 service vans with the XL3 Hybrid system. After 9 million service miles, the converted fleet showed 20 percent less fuel use than conventional vans. The move also contributed to the company’s goal of reducing its carbon footprint by 20 percent by 2020. The hybrid vans are expected to eliminate about 6,000 total metric tons of carbon dioxide emissions that conventional fuels would produce over their 10-year life span.

Read more: View a PDF of the Coca-Cola case study 

“This technology offered an option that provided low maintenance and fuel savings,” said Tony Eiermann, Coca-Cola North America fleet assets manager. “It was also able to work with our existing fleet structure.”

Coca-Cola continues to place orders with XL Hybrids. 

“We are scaling up,” Hynes said. “Most of our sales are repeat orders.”

A new plug-in product that converts Ford F-150s — the most popular truck in the country — is getting a lot of interest from utility companies that use them.

Hynes has a background in renewable-energy sources. As the industry took off, in 2008 he wanted to catch the next big thing to compete with oil.

“The thinking behind XL Hybrids was, ‘How can we start a company that is a good competitor with oil?’” he said.

Cody Friesen, an associate professor in the School for Engineering of Matter, Transport and EnergyThe School for Engineering of Matter, Transport and Energy is part of the Ira A. Fulton Schools of Engineering., reached out to Hynes and said the Avnet Innovation Lab could be helpful. Friesen is a veteran of two startup companies and founded the Avnet Innovation Lab.

ASU has inspired or assisted in the formation or growth of an estimated 1,000 startups. More than 500 people are now employed at ASU-linked startups. ASU inventions have attracted hundreds of millions of dollars in external funding, including $96 million in fiscal year 2016.

The Avnet Innovation Lab, in partnership with the Fulton Schools of Engineering, is designed to spur economic growth in the technology sector and enable aspiring entrepreneurs to advance their innovations.

“It really was a helpful connection for us, because we have a pretty extensive supply chain,” Hynes said.

As a startup, it’s hard to negotiate good deals. Starting a year ago, Avnet helped XL Hybrid review contracts and helped bid on some new agreements. The company continues to work with Avnet to get costs down.

“We’re open to talk if ASU wants us to make some shuttle buses more efficient,” Hynes said.

Scott Seckel

Reporter , ASU Now


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April 21, 2017

ASU students, community members and businesses team up to clean up Tempe butte

On hiking paths, under desert rocks and stuck on cactus thorns, trash left behind by hikers and visitors piles up every year on “A” Mountain until a group of volunteers braves the desert heat to clean it up.

On Friday, April 21 — in honor of Earth Day — community members, local businesses and the ASU community rallied to help keep Tempe’s only preserve clean at the the annual “A” Mountain Restoration.

The Julie Ann Wrigley Global Institute of Sustainability and the School of Sustainability partner with the city of Tempe to organize the event for the well-known butte with panoramic views.

“This is a mountain that is used, and overused and loved, and loved too well,” said Lauren Kuby, councilwoman and manager of events and community engagement for the Julie Ann Wrigley Global Institute of Sustainability. “So every Earth Day, the least we can do as a community is give back to this mountain.”


The mountain has a rich history that many Tempe residents might not know about: It was first home to the Hohokam who lived there around AD 700, according to Tempe city planner and architect Bonnie Richardson.

Petroglyphs dating back to when the mountain was surrounded by water are one of the main reasons this mountain is so special to the local landscape — and why restoring it is important to this group.

“We have about 100 people here. They’re devoted, and I’ve seen people come back too, along with new people. For them, it is a ritual.” Richardson said.

Companies like FedEx and Slickables, along with ASU student groups and Tempe residents, gathered at the base of the mountain at 8:30 a.m. They were supplied with garbage bags, trash pickers and rakes as well as coffee, hats, sunscreen, a sack lunch and, of course, water.

“We pick up tons of trash, literally,” Richardson said. “They’re raking, putting new gravel on the pathways and setting the rocks so that the paths are very well delineated.”

Richardson says that she has seen the city of Tempe grow significantly and that the turnout for this event is pretty steady. For her, it’s about preserving Arizona’s rich history and landscape.

“We call ourselves ‘sustainable Tempe’ for a reason,” Richardson said. “And the more we can get out with the community and share why it’s important is what’s important.” 

Reporter , ASU Now