Kenworth manufactures a variety of trucks. The company recently introduced its hybrid models.

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If there is one thing that Kenworth Truck Co. – a division of PACCAR – is known for, it is the manufacturer’s commitment to innovation. In the past several years, the company has been deeply involved in a program to create vehicles that are compliant with the 2007 EPA emissions standards, provide good fuel economy and are of the highest quality standards.

Headquartered in Kirkland, Wash., Kenworth specializes in the design, manufacture and service of high-quality heavy- and medium-duty trucks primarily for markets in the United States and Canada.

In 2007, new EPA emissions standards went into effect to reduce emissions, such as nitrogen oxides, hydrocarbons and particulate matter, from heavy-duty trucks. Assistant General Manager of Operations Marilyn Santangelo says the company is designing several new fuel-efficient vehicles that take fuel consumption and the emissions requirements into account.

Kenworth’s objective? Develop an environmental program focused on alternative fuels, hybrid technologies, idle reduction, aerodynamic performance and driver awareness technologies, the company says.

“Quality, technological innovation, customer service and environmental stewardship are all a big part of our world here at Kenworth, and we’ve had the foresight to have technology in place that meets the environmental needs for many years,” Santangelo asserts.

The company currently manufactures Class 8 heavy-duty trucks, which serve over-the-road and vocational applications, and Class 5-7 medium-duty trucks involved in local pickup and delivery, utility and many other applications.

Cutting Fuel Consumption
Kenworth’s commitment to producing industry-leading aerodynamic and fuel-efficient vehicles has been recognized by the EPA SmartWay program. Several Kenworth models are considered environmental leaders because of their aerodynamic packaging in the product design, including in the roof and fuel tank side fairings, bumper and mirrors, as well as improved engine efficiency.

In March 2006, the company introduced its most aerodynamic ever Class 8 model for the heavy duty market. The Kenworth T660 is ideal for long-haul transport, and has several design features that make it standout among other conventional haulers.

The T660 has a new fairing design that covers the toolbox, battery box, fuel and hydraulic tanks in a profile that enhances the aerodynamics of the vehicle and has strong crossmembers and custom frames for hauling.

“For Kenworth, offering a very aerodynamic product can be traced back to the mid-1980s,” Santangelo notes. “We took the lead in developing and offering the industry’s most aerodynamic trucks and keeping that lead is one of our key goals.”

Kenworth’s T660 can also come factory-installed with the new Kenworth Clean Power no-idle system. Clean Power uses advanced deep-cycle batteries that power a thermal storage cooler with 21,000 BTUs of cooling capacity. Once the truck is shut off, a thermostat regulates the desired temperature and a variable speed fan circulates chilled air through a duct located near the bunk, Kenworth says.

The company will also create a presence in the liquefied natural gas (LNG) market, beginning in 2009 with the production of its T800 LNG trucks at its manufacturing facility in Renton, Wash. In partnership with Vancouver, British Columbia, Canada-based Westport Innovations Inc., Kenworth will use Westport’s LNG fuel system technology adapted for the Cummins ISX 15-liter engine. LNG trucks are expected to meet the growing demand for environmentally efficient vehicles at the ports and other customers who work in non-attainment areas.

According to Kenworth, the LNG factory installation comes on the heels of an announcement by the Ports of Los Angeles and Long Beach to approve a new $1.6 billion Clean Truck Superfund. The fund will assist replacing many of the 16,800 Class 8 trucks serving the ports with LNG-powered vehicles. The ports have also introduced a new progressive plan that will remove all pre-2007 trucks by 2012.

Westport’s LNG fuel system is the only alternative fuel technology currently qualified for financial support under the ports’ Clean Truck program, Kenworth says.

21st-Century Technology
Kenworth is preparing to begin full production of its medium duty, diesel-electric hybrid trucks. These new vehicles will offer significant fuel economy improvements, particularly in urban and utility applications.

“Kenworth’s hybrid vehicles program targets goals of up to 30 percent in pickup and delivery applications and up to 50 percent in utility operations, which will help reduce vehicle operating costs,” Santangelo says.

Kenworth will offer the hybrid option on its new T270 Class 6 and T370 Class 7 conventional models and will produce the trucks at the PACCAR plant in St.Therese, Quebec.

The Kenworth hybrids use a transmission-mounted motor/generator; frame-mounted 340-volt, lithium-ion battery pack; and power management system. The trucks’ power train controls can monitor driving conditions and automatically select the ideal power mode, and switch from electric only to combined diesel and electric to diesel only.

Electricity on the hybrids is generated through what the company calls “regenerative braking” and is stored for when the vehicle needs to accelerate. The hybrid system can be monitored through a display on the dashboard, so as the power requirements change, the screen is updated. Kenworth is currently developing a hybrid model for its future heavy duty portfolio.

The company is rearranging its production areas at the plant in Ste. Therese, Quebec, to install the battery packs and other components that go into the new hybrid trucks. Santangelo admits that the company didn’t have to add too much to the production process, but did spend significant time training technicians about the new technology. “For us, new things are normal,” she says.

Capital Investments
“We have a lot of investment that increases the capacity at Kenworth on both the heavy- and medium-duty lines,” Santangelo notes. In March, Kenworth completed an expansion of its heavy-duty production plant in Chillicothe, Ohio, to increase plant size and production capacity.

The project added 105,000 square feet to the facility. The Chillicothe plant – Kenworth’s largest – has produced more than 300,000 trucks since it was opened in 1974. “[The] Chillicothe plant is one of the most advanced truck plants in the industry,” Santangelo says.

“The expansion further advanced Kenworth’s world-class quality and increased Chillicothe’s build capacity by 50 percent.”

The expansion project introduced new manufacturing technologies and processes, extended Chillicothe’s mainline; added new cab, sleeper, trim lines; enhanced ergonomics; and included exciting advancements in plant logistics. In addition, all Kenworth factories meet strict ISO 14001 environmental standards.

As the company invests in the new technology and capacity, it follows a lead plant strategy, where one plant makes an investment, implements the process and then the system is rolled out to other plants.

Kenworth heavy-duty trucks are produced in Kenworth plants in Chillicothe, Ohio; Renton, Wash.; and Mexicali, Mexico; and medium-duty trucks at the PACCAR plant in Ste. Therese, Quebec.

“Working with our employee teams and supplier partners, we’ll continue to make innovative application of new technologies, as well as continuously enhance quality. Aiming for zero waste-to-landfill rounds out our environmental strategy,” Santangelo asserts.

Industry Recognition
In August 2007, Kenworth further strengthened its reputation by achieving the highest ranking in customer satisfaction among Class 8 truck owners in the Over The Road, Pickup and Delivery and Vocational Segments, according to a J.D. Power and Associates 2007 Heavy Duty Truck Customer Satisfaction study.

Kenworth says it is the first truck manufacturer to sweep all three major product segment awards since the J.D. Power study was introduced in 2003. The 2007 study marked the third consecutive year that Kenworth received both the Over The Road and Pickup and Delivery awards, and at least three of the four Heavy Duty awards bestowed annually. Those honors increased its total to 11 Heavy Duty awards, which is more than any other truck manufacturer.

The 2007 J.D. Power and Associates study was based on interviews with 2,677 primary maintainers of Class 8 trucks.

“Kenworth’s engineering investments have focused on providing outstanding new innovative products that exceed customer expectations and contribute to their efficient operating results,” said Chief Engineer Mike Dozier in a statement. “The new Kenworth T660, Kenworth Clean Power no-idle system, and medium duty hybrid trucks have set the industry standard for enhanced performance and improved customer profitability. These new Kenworth products further expand the company’s successful product range which has been at the forefront of customer satisfaction for over eight decadesKenworth is very honored to earn all three 2007 Class 8 product segment awards,” added PACCAR vice president and Kenworth GM Bob Christensen. “Kenworth employees take great pride in designing and building the World’s Best products.”

EPA’s SmartWay Program
SmartWay Transport is a voluntary part-
nership between various freight industry sectors and EPA that establishes incentives for fuel efficiency improvements and greenhouse gas emissions reductions. By 2012, this initiative aims to reduce between 33 and 66 million metric tons of carbon dioxide (CO2) emissions and up to 200,000 tons of nitrogen oxide (NOX) emissions per year. At the same time, the initiative will result in fuel savings of up to 150 million barrels of oil annually. There are three primary components of the program: creating partnerships, reducing all unnecessary engine idling and increasing the efficiency and use of rail and intermodal operations. 

From ports to manufacturing facilities and distribution centers to one’s front door, trucks and rail systems are part of a sophisticated, fast-moving ground freight delivery system that delivers products safely and on time. Ground freight is an integral part of the United States economy. According to government and industry statistics, 85 percent of the total value of United States cargo is trucked, accounting for 66 percent of all freight by weight. Trucking-related occupations employ about 10 million people. Railroads represent four percent of the
total value of all freight by weight, carrying
another 16 percent of the nation’s freight
by weight. 

However, ground freight is a major source of greenhouse gas emissions, responsible for approximately 20 percent of CO2 emissions from all transportation sources. Ground freight is also a significant source of smog-forming emissions and other harmful air pollutants that impact public health, particularly the young and the elderly. Ground freight accounts for 40 percent of the oxides of NOX and 31 percent of the particulate matter emissions from transportation sources. These emissions can impact air quality and contribute to climate change.

Partnerships with companies such as Paccar are the foundation of the SmartWay Transport Program. Key partners are companies that ship products and the truck and rail companies that deliver these products. Partners commit to measure and improve the efficiency of their freight operations, using EPA developed tools that quantify the benefits of a number of fuel-saving strategies.