As fleet operations become more complex, a recent survey of U.S. fleet managers highlights the expanding role of fuel cards in managing costs, improving data visibility and supporting emerging technologies like electrification.

Insights from 260 U.S. Fleet Managers

In early 2025, Shell Fleet Solutions surveyed 260 U.S.-based fleet managers to better understand how they manage fuel expenses and operational complexity. According to the results, 62% of fleets currently use fuel cards, with adoption rates higher among larger fleets (70%) compared to small businesses (60%).

Among all surveyed managers, 95% said fuel cards provide valuable insights into fleet efficiency, making them a top tool for data-driven decision-making — not just transaction tracking.

Key Benefits: Expense Control and Efficiency

Fleet managers rank easier fuel expense tracking (49%), improved budgeting (47%) and the ability to set spending limits (43%) as the most common advantages of fuel card use. Larger fleets also emphasized security and integration:

• 55% cited better control over unauthorized fuel usage

• 47% noted integration with fleet management systems

• 45% valued wide station network access

Small businesses, meanwhile, were more likely to focus on the cost-control features of fuel cards.

Data and Cost Challenges

The top challenges facing fleet managers include:

• Cost-reduction initiatives (32%)

• Complexity in fuel data consolidation (28%)

• Compliance with environmental regulations (28%)

Larger fleets reported more issues with data complexity and cost control, while small fleets struggled more with driver reporting and accountability

Despite the growing use of digital tools, 25% of fleet managers still track fuel expenses using spreadsheets and another 25% record expenses by hand, underscoring the need for further digitization.

Security: A Persistent Barrier

While most fleet managers view fuel cards as beneficial, security remains a leading concern.

• 78% of managers agree that a lack of advanced security features is a deterrent

• 75% say general security risks make them hesitant to adopt digital card tools

Non-users also cited limited acceptance networks (18%) and administrative effort (17%) as additional barriers.

Fuel Card Technology Responds

In response to these concerns, newer fuel card platforms now include:

• Advanced encryption and secure data transmission (AES and TLS)

• Biometric authentication via mobile apps

• Level III data collection, including odometer readings, driver ID and vehicle VINs

• Expanded station access, with the Shell Card Business Flex accepted at 95% of U.S. fueling sites

Futureproofing Fleets for EV Integration

The Shell Card Business Flex also supports EV charging at public and residential stations, helping fleets transition to electrification while maintaining unified billing and data reporting.  Additional support is available through Shell’s Accelerate to Zero program, designed to guide large fleets toward long-term sustainability goals.

The report makes clear that fleet managers increasingly see fuel cards as multifunctional platforms:

• Cost management

• Operational insight

• Security and compliance

• EV readiness

Yet, adoption gaps remain, especially among smaller fleets and managers wary of digital risks. As tools evolve to address these concerns, fuel cards are poised to become a cornerstone of integrated fleet management.