Navigating market complexity: aftertreatment systems in off-highway applications

Cummins is a global leader in off-highway emissions solutions. With over 105 years of experience, 25 technical centers worldwide, Cummins is at the forefront of designing, integrating, manufacturing, and distributing exhaust aftertreatment systems. Our mission? To help customers meet today's stringent emissions standards while preparing for tomorrow's regulations.

Off-highway applications: broad and varied

The off-highway sector is incredibly diverse, covering everything from stationary applications to agriculture and construction. Each category has its own unique needs, with power requirements ranging from compact 49-horsepower engines to large-scale of over 4,400-horsepower systems. These environments often present harsh operating conditions that test durability and performance.

The complexity of this market isn’t just about the variety of applications but also involves a variety of duty cycles. Each application requires a customized approach, and Cummins excels in delivering solutions that perform and adapt across this varied landscape.

Off-highway regional and regulatory variations

The global nature of the off-highway market adds another layer of complexity. Emissions regulations vary significantly between regions, requiring solutions that balance compliance, performance, and cost-effectiveness.

• North America, the European Union, Japan, South Korea markets: emission regulations (EPA Tier 4, EU Stage V, JMLIT and KMOE) are stringent and generally equivalent. Cummins has developed single-product solutions that meet these regulatory requirements. This allows original equipment manufacturers (OEMs) to streamline their operations and offer standardized products across multiple geographies without sacrificing compliance.
• China and India: these markets have seen rapid regulatory advancements in recent years. While China’s emissions standards are similar to North America s, its NOx requirements are less stringent. India’s standards are comparable to Europe’s Stage V but require cost-effective, fit-for-market products. Cummins designs solutions that balance these regulatory demands with market-specific requirements to ensure affordability and reliable performance.

Horsepower considerations

Regulations also vary by engine horsepower (HP):

• Engines below 74 HP (Agriculture, construction and power generation markets): the aftertreatment needed in this space is primarily geared towards particulate matter (PM) control. This drives the use of simpler architectures like DOC only or DOC and DPF only. Cost and fitment are the primary drivers in this space.
• Engines between 75 and 750 HP (mainly in the construction and agriculture market): this is a more complex landscape, with regulatory requirements diverging based on application. Compactness, configurability, reliability, and serviceability in aftertreatment systems are key to ensuring equipment runs efficiently and safely. These engines have a full aftertreatment system. 
• Engines above 750 HP (mining, oil and gas, marine applications): although regulations are less stringent in this HP range, Cummins prioritizes CRS systems  control NOx. Reliability, system  integration, and total cost of ownership become even more important given the long life expectancy. 

Meeting off-highway customer needs

Understanding and addressing customer needs is key to Cummins’ approach. For OEMs, choosing the right aftertreatment system boils down to the following considerations: size, configurability, maintenance, and durability. These elements not only impact performance but also play a big role in end-user satisfaction and operational efficiency. 

• Size and Configurability: Space is often at a premium in off-highway equipment design. That's why compact systems that fit seamlessly into machinery are essential. This is especially true in agriculture and construction, where visibility is crucial. For instance, in agricultural tractors, aftertreatment systems are placed below the driver's line of sight or behind pillars to maximize visibility while staying compliant.
• Maintenance and Durability: Off-highway environments can be tough, so systems need to be both robust and easy to service. Downtime for maintenance can seriously affect productivity, making durability a top priority. Cummins' systems are built to last and are designed for easy maintenance, ensuring they perform consistently even in challenging conditions.

Overcoming additional challenges

Beyond size, configurability, and durability, there are other hurdles that shape product development and customer decisions.

• Fuel Variability: Off-highway applications often use various fuel types and qualities, especially in regions with different fuel standards. Machinery with aftertreatment systems must adhere to fuel specifications as mandated by the applicable emission regulatory agencies. To enable to use of green fuels, our aftertreatments have been designed to be used with up to B20 fuel and 100% HVO for most engines. 
• Service Channels: The global nature of the off-highway market requires a reliable service network. Cummins supports customers with a robust service infrastructure, making sure technical expertise and replacement parts are always available when needed.
• Space Constraints: Integrating aftertreatment systems into machinery can be a persistent challenge. Cummins tackles this by offering highly configurable solutions. For example, for high-horsepower mining equipment, Tier 4 engines with aftertreatment maintain the same “drop-in” space as Tier 2 equivalents.  

Off-highway emission solutions for today and tomorrow

At Cummins, we're dedicated to leading the charge in off-highway emissions solutions. With decades of experience and a deep understanding of regional and application-specific needs, we deliver innovative, reliable, and adaptable systems. Our solutions help customers meet even the toughest emissions standards. Whether it's navigating complex regulations or tackling harsh operating conditions, Cummins Emission Solutions ensures you have the best solutions for today and tomorrow.