CASE STUDY
Secure, Scalable Fueling System for a Top-5 U.S. Metro Fleet
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Overview
We developed and deployed a high-performance, security-hardened fueling management platform for one of the five largest U.S. metropolitan fleets. The solution ensures uninterrupted fueling operations and centralized oversight across:
21,000+ fleet equipment units
130,000+ fuelings per quarterunits
65 fueling sites across
50+ city departments units
All municipal vehicles, including first responders, sanitation, transportation, and public works
Engineered for mission-critical uptime, the platform delivers real-time control, ruggedized hardware integration, and fully encrypted communications—while significantly reducing data costs, eliminating operational errors, and generating measurable business value.
The Challenge
The city’s legacy fueling system had become increasingly unreliable as fleet size and data volumes grew. It struggled to meet operational demands and introduced critical inefficiencies. Major issues included:
Severe slowdowns due to accumulating unindexed historical data, causing sluggish response times and daily operational delays
Frequent software crashes that disrupted fueling and increased IT workload
Inaccurate transaction logging, often failing to reflect actual fuel dispensed—leading to billing discrepancies and audit concerns
No centralized dashboard for monitoring site activity, tank levels, or system health
Manual retrieval of Veeder Root tank data, with no real-time integration across sites
Excessively high cellular data costs, driven by unoptimized communication protocols that retransmitted full unencrypted vehicle whitelists and site data with every change—including vehicle updates, site edits, or fuel allowance modifications. This resulted in repetitive, redundant, and insecure sync activity across all sites
The city required a robust, always-on solution that could operate independently at remote fueling stations while delivering secure, centralized control—without ballooning operational overhead.
The Solution
We engineered a custom-built fueling ecosystem using .NET Core, combining secure APIs, ruggedized embedded hardware, and a centralized architecture designed for scale, resilience, and real-time performance.
Embedded Hardware Integration
Our custom fueling controller included:
RFID vehicle identification for fast, secure, hands-free authentication
Secure APIs & Encrypted Communication
Enabled encrypted TCP socket communication between site terminals and the central server
Developed a proprietary dual-layer encryption and compression protocol that reduced payload sizes by 50–60% prior to transmission. Unlike conventional encryption methods that increase data size, our approach preserved security while optimizing bandwidth—contributing directly to an 80% reduction in cellular data usage
Synchronization & Real-Time Oversight
Our custom fueling controller included:
Performance Engineering
Improved transaction speed by 300% through optimized data flow and high-efficiency SQL queries
Delivered a modular, scalable backend designed for low maintenance and seamless future expansion
Results & Impact
The platform now powers one of the largest and most complex municipal fueling operations in the United States—with unmatched speed, visibility, and control.
- 99.5% system uptime, ensuring continuous fueling access for all city departments and emergency responders
- 300% faster fueling terminal response and transaction speed
- 80% reduction in data transmission load and cellular communication costs
- Real-time, end-to-end encrypted data handling across 65 fueling locations and 50+ departments
- Centralized audit, live monitoring, and full Veeder Root tank level integration
Financial & Operational Benefits
Fuel Theft Prevention & Cost Recovery
Real-time auditing, encrypted user validation, and fuel usage limits eliminated theft and misuse—saving the city hundreds of thousands annually.
Accurate Departmental Billing
Every transaction is now linked to the correct department and vehicle, enabling precise usage-based billing and improved interdepartmental cost forecasting.
Fleet Efficiency & Performance Insights
Fuel consumption data revealed underperforming or inefficient vehicles, enabling proactive maintenance, replacement planning, and optimized lifecycle management.
Key Innovations
Our custom fueling controller included:
Technology Stack
| COMPONENT | TECHNOLOGY |
|---|---|
| Frontend | ASP.NET Razor, Bootstrap |
| Backend | .NET Core 6, Entity Framework, LINQ |
| APIs | RESTful JSON APIs, JWT auth, HTTPS |
| Security | AES-256 encryption, client certificates, RBAC |
| Networking | Encrypted TCP socket services |
| Database | SQL Server with partitioning, replication, indexing |
| Hardware | RFID boards, manual scan keys, coil sensors |
| Hosting | On-premise Windows Server cluster with redundancy |
