Whether you’re operating in the truckload (TL) or less-than-truckload (LTL) segments, the conversation around trailer weight savings has gained significant traction recently.
Mark Schultz, who serves as Great Dane’s Dry Freight Product Director, offers insight into the subject.
“This shift is driven by two key factors: stricter diesel engine requirements and the rising adoption of electric tractors, both of which add extra weight to the vehicle. To overcome these challenges, reducing the weight of trailers has become critical to our customers,” Schultz said.
The question that may be most important for your fleet is, should you aim for weight reduction to save on fuel costs or to maximize your payload capacity?
“This is the first question we ask our customers. We can customize their trailers to meet their specifications depending on their answer,” Schultz explained.
Why Weight Reduction Matters
“Extra trailer weight has a direct impact on a fleet’s profitability,” explained Barry Personett, Vice President of Product and Sales Engineering for Great Dane. “Heavier trailers consume more fuel, reduce mileage, and increase wear and tear on critical components. That’s why our engineering team designs features that offer increased durability while reducing weight.”
Weight savings can benefit your fleet in two specific ways:
- Save on Operational Costs – Reduced trailer weight means improved fuel economy, which is essential as fuel costs continue to rise.
- Increase Payload Capacity – Lighter trailers allow you to carry more goods per trip, leading to higher delivery efficiency and profitability.
Weight-Saving Solutions for Your Fleet
Lightweight Deck and Floor Options
“One of the biggest areas that can contribute to trailer weight reduction is the deck and flooring,” Schultz said. “We offer several solutions that help our customers experience weight savings while still providing the quality and durability they expect from Great Dane.”
This includes:
- Composite Floors – Our lightweight composite floors are just as strong as traditional hardwood options but come with significant weight savings.
- Aluminum Outboard Floorboards – Replace wood with aluminum on outer areas where there is less wear and tear from forklifts.
- Full Aluminum Floors – For fleets ready to go fully lightweight, aluminum floors eliminate the use of wood.
“By rethinking the materials used in your trailer flooring, you can reduce overall weight without compromising reliability or durability,” Personett added.
Lightweight Sidewalls and Roof Bows
“Sidewalls are another area where weight savings can be achieved. For fleets transporting evenly distributed loads, we provide lightweight sidewall options that maintain structural integrity while reducing weight,” Schultz explained.
We can also equip your trailer with aluminum-extruded roof bows, offering another layer of efficiency for the upper structure of your trailer.
Aluminum Suspension Components
Every pound saved on suspension components adds up. That’s why we provide innovative solutions like:
- Aluminum Wheels – Replace traditional steel wheels for substantial weight reductions.
- Wide Base Tires – These tires help cut weight while improving rolling resistance.
- Lightweight Wheel Hubs – Swapping steel hubs for lightweight alternatives can save weight at the wheel ends.
- Air Disc Brakes – Modern air disc brakes offer both weight savings and enhanced braking performance, improving safety and efficiency on the road.
Advanced Crossmembers and Lining Options
At Great Dane, we equip every inch of our trailers with features that offer exceptional efficiency and durability, including the underpinnings of the trailer’s structure, which should be as efficient as possible. But Schultz explains there are important factors to consider before deciding to reduce your trailer’s weight.
“Using aluminum crossmembers along with full aluminum floors saves weight, but it also reduces strength to the floor and deck rating. So, it’s important to consider your overall pallet weight, forklift weight, and cycles when you’re deciding on weight-saving options. We can help you when you’re considering these factors and suggest the best options that match your operational requirements,” Schultz said.
For sheet and post trailers, you can also opt for lightweight lining options that are designed to replace conventional plywood.
Modular Configurations to Fit Your Needs
It’s important to remember that there’s no one-size-fits-all solution. We’ll work with you to identify the right combination of weight-saving components for your operation. Whether it’s swapping materials, integrating advanced design features, or choosing modular components, our goal is to help you maximize efficiency for both payload and fuel economy.
The Benefits of Investing in Weight Optimization
Weight savings isn’t just a buzzword—it’s a strategic investment. By adopting lightweight components, businesses in the TL and LTL delivery sectors can unlock measurable advantages, such as:
- Improved Fuel Economy – Reducing trailer weight improves mileage, helping you lower operating costs over time.
- Higher Profit Margins – Hauling more goods per trip means fewer trips overall, boosting your ROI.
- Regulatory Compliance – Staying within weight limits ensures that your fleet complies with industry regulations, avoiding costly fines and penalties.
By rethinking your fleet’s build, you can position your business competitively for the challenges of the road.
Make Every Load Count
When it comes to optimizing your fleet, every pound matters. Reducing the weight of your trailers can not only help you achieve long-term cost savings but also create opportunities for scaled-up payload capacity. Whether you’re looking to save on fuel costs or increase payload capacity, we’re ready to tailor a solution that fits your needs.
Let’s get you on the road to greater weight savings and increased durability for the long haul.
Contact us so we can get started today!
