How Nussbaum Cut Idle Time to <1% with Merlin Solar
- Merlin Solar Team
- Nov 10
- 3 min read
Updated: Nov 18
Rising Fuel Costs Spark a Search for Smarter Power
Rising fuel costs and operational inefficiencies are challenging fleets nationwide. For Nussbaum Transportation, a leader in commercial logistics, cutting idle time was key to staying competitive. The solution came from a proven source of power: Merlin Solar.
The Challenge
Fleet operators across the U.S. face rising expenses on every front — from fuel to maintenance.
According to the U.S. Department of Energy, vehicle idling consumes more than 6 billion gallons of fuel every year, costing businesses and consumers over $20 billion.
For Nussbaum, idling wasn’t just burning fuel — it was shortening battery life, adding wear on starters and alternators, and driving up maintenance costs. They needed a proven way to keep trucks powered without running the engine.
The Solution
To combat inefficiencies, Nussbaum equipped 70% of its fleet with Merlin’s flexible, high-performance solar panels. Each system produces just over 500 watts of clean power, seamlessly integrated into the truck’s roof for a low-profile, aerodynamic fit.
As Nussbaum explains in their own blog, “The Solar Advantage”:
“To help reduce idle time and maximize battery life… we save one gallon of diesel fuel for every hour of reduced idle time.”
These panels allow drivers to power auxiliary systems during breaks without idling.
“Truck-mounted solar has advanced quickly, and Nussbaum relies on months of real-world, route-based testing to separate marketing claims from true performance. Across multiple solar kits evaluated under identical conditions, Merlin continues to stand out. Its panels have consistently delivered stronger real-world power generation, exceptional durability, and reliable output even in low-light and variable-weather environments. Based on our ongoing fleet-level testing, Merlin remains the clear choice for long-term performance and operational reliability.”
— Tony Morthland, Director of Equipment and Facilities at Nussbaum Transportation
November 18, 2025
“These panels produce just over 500 watts and fit perfectly in the indentation in the roof. They look great and perform great. These things just work.”
— Clark Reed, Nussbaum Transportation, a TCA Professional Driver of the Year for 2024
Proven Results
Fuel Efficiency: Nussbaum saved roughly 1 gallon of diesel per hour of reduced idle time. At the time of the case study (2022), the national average diesel price was $5.57/gallon, making the savings up to $66.84 per driver for 12 hours of idle time eliminated during a typical 34-hour weekend.
Idle Time Reduction: On monitored trucks, idle time dropped from 15% to less than 1% after installing Merlin panels. Across the full fleet, Nussbaum reports an average reduction of 4.2% in their blog “The Solar Advantage”, providing a conservative, fleet-wide perspective that aligns with Merlin’s measured results.
Extended Battery Life: Before installing Merlin panels, batteries lasted about 18 months. Now, they last 3–4 years — a 2.5× improvement.
Reduced Maintenance Costs: Less strain on electrical systems led to a 70% reduction in battery replacement costs, while starters and alternators last longer.
The Outcome
By deploying Merlin’s rugged, flexible solar panels, Nussbaum reduced fuel use, extended battery and component life, and improved overall fleet efficiency.
Key results include:
Up to 12 hours of idle time eliminated per driver each weekend
<1% average idle time on monitored trucks
2.5× longer battery life
70% reduction in battery replacement costs
This case demonstrates how practical, innovative solar technology delivers measurable, repeatable results, transforming commercial transportation operations.
