Fuel consumption is a significant cost for any company managing a larger fleet, whether that fleet consists of freight vehicles, heavy machinery or agricultural equipment. The PratiMe system offers advanced solutions for monitoring and controlling fuel consumption using fuel sensors, known as probes. These sensors provide precise, real-time data on fuel level, allowing companies to track refueling, cut costs and effectively prevent fuel theft.
Before measuring with a probe, you can get a rough estimate of consumption with our free fuel consumption calculator.
For tankers and fuel transport, where transfer between tanks is also monitored, see our solutions for the oil industry.
How fuel sensors work
Fuel sensors, or probes, are installed in vehicle tanks and enable precise measurement of the fuel quantity at every moment. These probes send data to the GPS tracking system, where the information can be monitored via web or mobile apps. Using fuel sensors, you can track every change in fuel level, detect the exact moments of refueling and draining, and analyze total consumption over defined time periods.
The main functions of fuel sensors include:
- Precise measurement of the current fuel level.
- Detection of refueling and draining events.
- Real-time fuel consumption tracking.
- Sending an alarm for sudden changes in fuel level (theft, unauthorized draining).
Benefits of installing fuel sensors
Installing fuel sensors brings numerous benefits to companies looking to optimize their operations and reduce costs related to fuel consumption. One key benefit is preventing fuel theft, a common problem across many industries. Sensors provide instant information about every drop in fuel level, together with the exact location and time the change occurred.
The benefits include:
- Preventing fuel theft through accurate detection of changes in fuel level.
- Precise tracking and logging of every change in the tank.
- Greater fleet management efficiency through automatic consumption control.
- Lower operating costs through optimized fuel consumption.
Probe installation and calibration
Proper installation and calibration of fuel probes are key factors for the accuracy of the data collected. The PratiMe system uses high-quality fuel sensors, but it is crucial that the installation pays attention to the tank's geometry and technical layout. A poor installation can lead to inaccurate data, fuel leaks or problems with the electrical wiring.
The steps for a proper installation include:
Analytics and reports from the tracking system
All data collected through fuel sensors is displayed within the PratiMe platform, where users can review detailed reports and analytics. The system enables real-time data review, as well as analysis of historical data through charts and text reports. The system also sends alarms by SMS, email or notification, enabling a fast reaction in case of unauthorized activity.
Key report features include:
- Graphical display of alarms within the app.
- Fuel consumption reports over different time intervals.
- Detailed analysis of the locations and times where changes in fuel level occur.
- Alerts for a drop or rise in fuel level, with notifications sent.
Get complete control over fuel consumption across your fleet with the PratiMe system and advanced fuel sensors. Get accurate information, prevent theft and cut business costs. Contact us at podrska@pratime.rs or call 065 9007380 to find out more about our solutions for fuel monitoring and business process optimization. With the PratiMe system, your vehicles are always under control!
How a fuel probe actually works
A probe is a measuring rod installed in the tank that continuously measures fuel level. Unlike the factory gauge in the vehicle, which only gives the driver a rough picture, the probe produces measurable values that the system logs and stores.
Level is measured, consumption is calculated
The probe measures how much fuel is in the tank at every moment. Consumption is calculated from the change in level over time, while refueling and draining are recognized as sudden rises or drops. This makes it possible to separate normal consumption from an unexplained loss.
Why calibration is a required step
Tanks are not a regular shape, so the same drop in level does not mean the same amount of fuel at the bottom and at the top of the tank. That is why each probe is calibrated for the specific vehicle - the tank is filled in steps and the system records the relationship between the measured height and the actual volume. Without this step the data looks tidy, but it is not accurate.
Probe or data from the vehicle's electronics
Fuel data can also be read via a CAN BUS adapter, directly from the vehicle's electronics. This is a simpler solution, but its precision depends on the vehicle itself. When the goal is detecting theft, a probe gives a measurement you can rely on, so in practice these two approaches are often combined.
How the system detects fuel theft
Fuel theft rarely looks dramatic. Most often it is a series of small losses that get lost in the monthly average. A probe makes them visible, because every drop in level is logged with the exact time and location.
- Draining from the tank - a sudden drop in level while the vehicle is standing still, most often away from base and outside working hours.
- Short fill - less fuel goes into the tank than the receipt states.
- Unrecorded fill - the level rises, but no matching receipt exists.
- Consumption that doesn't track mileage - visible only once fuel data is compared with the route traveled.
For each of these events the system sends an alarm by SMS, email or notification, with location and time. Instead of looking at summary figures months later, you react to a specific event while it is still possible to establish what happened.
Where probes are most commonly installed
- Trucks and freight vehicles - large tanks and long routes, where even a small percentage of loss adds up to a significant amount (commercial vehicle tracking).
- Heavy machinery - excavators, loaders and generators that burn fuel on the spot, where mileage says nothing about consumption (heavy machinery tracking).
- Agricultural machinery - seasonal work and refueling in the field, far from base (agricultural machinery tracking).
- Stationary tanks - internal pumps and tanks at the base, where you track stock levels rather than a vehicle.
Probe, CAN bus or smart cap: what makes sense
Not every vehicle needs a probe. On vehicles with a single tank, fuel level and consumption can often be tracked well directly from the vehicle's CAN bus, with no work on the tank. On vehicles with two tanks, we recommend installing LLS probes for precise tracking of the level in both.
As an extra layer of protection, smart fuel caps are installed, which log every opening and closing of the tank. If the area around the tank is also covered by a camera, you get the highest level of control: fuel level data, the cap event log and the video footage can be cross-checked against each other, so a suspicious drop in level is no longer interpreted, it is seen.
Frequently asked questions about fuel sensors
Does installing a probe damage the tank?
Installation involves an opening on the top of the tank, through which the probe is fitted and sealed. The work is done by a trained technician, since the quality of installation determines both the accuracy of the data and safety. An unprofessional installation can lead to fuel leaks or problems with the electrical wiring, which is why this is not a job for improvisation.
Does a probe work on every vehicle?
The probe is adapted to the shape and depth of the tank, so the specific vehicle is always checked before installation. A solution exists for freight vehicles, heavy machinery, agricultural equipment and stationary tanks, but the choice of probe and the installation method differ.
What if the vehicle has two tanks?
In that case two probes are installed, and the system shows both the combined total and each tank separately. This matters because a loss can occur on only one side and would otherwise be lost in the combined figure.
Does fuel control work outside Serbia too?
Yes. The system works across all of Europe, so refueling and draining are logged the same way on international routes as well. For companies driving into the EU that means fuel is tracked for the whole trip, not just up to the border.
How much does fuel control cost?
Probes are an add-on module alongside basic GPS tracking, priced from 8 € per vehicle per month. You can test the system free for 15 days - see the pricing details or call us for a quote based on your number of vehicles and tank type.
Probe or CAN bus data, which do you recommend?
It depends on the vehicle. On vehicles with a single tank, fuel level and consumption can often be tracked well directly from the vehicle's CAN bus, without a probe. With two tanks, we recommend LLS probes in both for precise tracking.
What are smart fuel caps?
Caps that log every opening and closing of the tank. They are installed as an extra layer of protection alongside the probe, and if the area around the tank is covered by a camera, the fuel data, cap events and video footage can be cross-checked against each other.
