The American Transportation Research Institute’s most recent report on fleet costs, An Analysis of the Operational Costs of Trucking, showed that non-fuel operating costs hit their highest level ever, rising 3.6% $1.779 per mile.
At the same time, carriers have been under intense pricing pressure, leaving them with even thinner margins. The ability to control costs has become a competitive differentiator. Fleets with predictable, well-managed cost structures are better able to handle shifts in demand, economic volatility and increased operating expenses, but cost control doesn’t hinge on a single decision or department. It is shaped by several factors across the operation.
Equipment Strategies Shape Total Cost of Ownership
Medium- and heavy-duty trucks and trailers are significant capital investments, and the right equipment acquisition strategies play an important part in fleets’ overall costs. ACT Research reported in its 2026 outlook that many fleets entered 2026 with aging equipment and extended trade cycles, due in part to higher equipment prices and financing costs.
While upfront equipment costs are the most obvious expense, other equipment costs go beyond the initial purchase price. Maintenance, repairs, tires and downtime all contribute to the total cost of ownership. Delaying new equipment too long can ultimately increase costs due to decreased fuel efficiency and unplanned downtime. Breakdowns are especially costly, not only in repair expenses, but also in lost revenue, missed deliveries and reduced asset utilization.
Labor and Insurance Costs Remain High
Labor and insurance costs make up a significant part of a fleet’s total budget. While driver availability has improved in some segments, wages, benefits, recruiting, training and retention costs remain high. The National Transportation Institute estimates that replacing a driver costs between $7,000 and $10,000.
Insurance premiums have risen sharply in recent years amid higher labor and equipment costs, larger settlements and a rise in nuclear verdicts. Equipment can contribute to both cost areas. Late-model equipment offers more comfort and safety features, which can directly impact driver satisfaction and highway safety.
It Is a Competitive Freight Market
The trucking industry is highly fragmented, with more than 99 percent of carriers operating fleets with 100 trucks or fewer. According to the American Trucking Associations’ American Trucking Trends report, there are roughly 580,000 authorized interstate motor carriers. A fragmented market drives competition, especially on freight rates. The report noted that excess capacity and softer consumer spending have kept rates under pressure. Shippers also face cost pressures and frequently prioritize price, leaving carriers with limited ability to pass along the higher operating costs they’re experiencing.
Cost Control as a Foundation for Resilience
Effective cost control is about building flexibility and resilience, not simply cutting expenses. Companies that actively manage their total cost of ownership, asset utilization and network efficiency are better equipped to respond to demand volatility, capital constraints and shifts in the market. Cost discipline also frees capital for other areas, including safety programs, emissions reduction, digital tools and network optimization that improve efficiency over time.
Different approaches to equipment acquisition, capacity sourcing and logistics management can each serve as levers to balance risk, maintain cash flow, and improve performance.
Work With Penske
Penske can work with fleets and shippers to control costs and increase operational flexibility. Solutions include:
Leased Trucks and Trailers: Full-service leasing guarantees predictable costs and supports more accurate budgeting while giving fleets access to late-model equipment, a data-driven preventive maintenance program, 24/7 roadside support, and replacement equipment, which improves service.
Rental Trucks and Trailers: Fleets that can scale assets up or down, align equipment to specific use cases and avoid unnecessary capital expenses can respond to the market faster. Rental trucks and trailers give companies quick access to equipment right when they need it.
Used Trucks: As new equipment prices rise and higher interest rates compound costs, used trucks offer a lower-cost way to expand or refresh a fleet while stretching capital further. They also enable fleets to add capacity, test new routes or applications, and adjust equipment sizes without committing to large upfront investments or long depreciation cycles.
Logistics Services: Third-party logistics providers (3PLs) can help shippers identify opportunities to increase efficiency through network design expertise, real-time visibility, access to multiple transportation modes and dedicated capacity. 3PLs can also help shippers respond quickly to market needs and scale up or down as demand changes.
Ready,Gov
From left to right: Art Vallely, president of