Maintaining a Well-Oiled Machine: Fuel Strategy at Piedmont Airlines

Fuel is the invisible engine and a necessity for all airlines to operate every day. It’s also the second biggest expense for any airline after payroll. Our fleet of Embraer 145 aircraft consume about 180,000 to 200,000 gallons of fuel a day, with about 30,000 gallons used solely for taxiing the aircraft to and from the runway. That totals to 5 to 6 million gallons per month, costing between $13 – $15 million per month, or roughly 63 million gallons and $157 million annually. To operate safely, efficiently, and within budget, a wide network of teams work behind the scenes to manage every aspect of our fuel strategy from how fuel reaches our aircraft to determining the precise amount needed for every flight.

At Piedmont, we fly to more than 70 destinations along the East Coast and Canada. In each of these locations, we work with an established fuel vendor that is responsible for delivering and servicing fuel directly into our aircraft and a fuel supplier that provides the fuel itself. The majority of jet fuel consumed by our aircraft is produced domestically at refineries across the Eastern United States. From there, it’s transported via pipeline either directly to the airport, or to a regional fuel terminal.

“Fuel terminals are essentially like a railroad network,” says Jake Patton, Manager of Fuel Operations at Piedmont. “It’s not just jet fuel moving through those pipes, it’s everything from heating oil to gasoline and diesel, all flowing to their destinations.” Patton is one of 28 people based at American Airlines’ headquarters in Dallas who oversee the end-to-end logistics and contracts for fuel sourcing and delivery across both mainline and regional carriers. From these terminals, fuel is typically delivered to airports by tanker trucks, which is especially common at smaller stations.

“Typically, our fuel vendors remain contracted with Piedmont unless we discontinue service at a location. It’s our job to ensure that the aircraft fuelers are properly trained and regularly audited on Piedmont’s fueling procedures and safety protocols established by our Quality Assurance team,” says Donna Kinley, Maintenance Vendor Coordinator. “Proper storage, quality fuel, safe equipment, training, and vendor accountability are all reviewed during Quality Assurance audits,” says Steve Hertz, Piedmont Quality Assurance Manager. “These procedures guarantee that clean fuel is delivered to our aircraft, supporting a safe and reliable product for our customers.”

Two of our crew bases are in Charlotte, NC and Philadelphia, PA with majority of our routes departing from one of these bases and returning to the same location later in the day. Since these are American Airlines hubs with high aircraft volume, fueling here is significantly more cost-effective. To save on costs, our aircraft are typically fueled at these bases, reducing the frequency to refuel at smaller, more expensive spoke stations known as “tanker cities.” “Fuel prices vary widely depending on the market,” Patton explains. “At spoke stations, we often see costs that are 5% to 50% higher per gallon than what we pay at our hubs in Charlotte or Philadelphia. Right now, the average price is about $2.30 a gallon, but that number shifts with seasonal trends.”

The Embraer 145 holds about 1,690 gallons of fuel, but fewer than 1% of flights are fueled to capacity since extra fuel adds weight and reduces passenger load. “If we’re carrying a full load of passengers, we may only fill the tanks to about 80%,” says Todd Schink, Flight Operations Engineer at Piedmont. “On average, our aircraft depart with the fuel tanks about 50% full.”

Fuel planning is a delicate balance. Too little fuel can result in a diversion; too much fuel can result in weight restrictions and operational delays. Adding to that complexity, passenger weight assumptions change by season. From November 1 to April 30, the Federal Aviation Administration, (FAA) the standard average weight for each passenger is five pounds heavier than in the summer months of May 1 to October 31, due to additional clothing and gear. That seasonal difference means a winter flight could carry approximately 250 more pounds than the same flight in summer, which impacts how much fuel can be loaded without exceeding weight limits.

There’s no one-size-fits-all formula for fueling a flight. Dispatchers use tools like the Statistical Contingency Fuel (SCF) report, which analyzes historical data to help avoid over fueling while planning for the unexpected. Over fueling increases costs and can create operational issues. Aircraft have a Maximum Takeoff Weight (MTOW), and if exceeded, fuel may need to be burned off before takeoff. Since offloading fuel is rarely an option, precision is key.

Under fueling poses risks too, aircraft may have to return to the gate, causing delays. Weather, runway conditions, and potential diversions also impact fuel planning. “If there’s a chance of a diversion, we may reduce the passenger count to stay within weight limits,” explains Jason Culver, Director of Operational Control. ” Runway construction or wet conditions from rain and snow also affect stopping distance and requires more runway length in case takeoff needs to be aborted. Additionally, FAA regulations require every flight to land with at least 45 minutes of reserve fuel. “We plan to carry extra fuel beyond what’s needed enroute to ensure safety, meet regulations, and handle unexpected factors,” says Schink. “The goal is to avoid using reserve fuel on 99.9% of flights.”

Every aspect of Piedmont’s fuel strategy is measured with precision, and efficiencies are implemented wherever possible to reduce costs. For example, using a single-engine taxi saves approximately one gallon of fuel per minute, which can translate to nearly $10 million in annual savings. Limiting the use of the Auxiliary Power Unit (APU) at the gate can save an additional $3 million each year. Flight conditions and decisions in the air also play a major role. Flying at higher altitudes, where the air is thinner, improves fuel efficiency. In contrast, flying at higher speeds burns more fuel, while lower speeds conserve it. Headwinds increase fuel burn, whereas strong tailwinds can lead to significant savings.

Every opportunity to reduce fuel consumption or increase efficiency directly impacts the airline’s profitability. While not every fuel-saving practice applies equally to every operation, Piedmont’s route network is relatively fixed, with consistent altitudes and flight patterns. This consistency limits operational changes, but allows for highly accurate data collection giving us the ability to better monitor, adjust, and improve fuel efficiency across the airline’s entire operation.

Fuel is far more than just a line item on a budget, it’s a vital element that touches every aspect of our business, where every drop truly counts. Even though fuel remains one of the industry’s most significant expenses, Piedmont’s commitment to precision, safety, and strategic planning keeps our operation running smoothly and ensures our passengers keep moving forward.