A new report shows that commercial vehicles are much higher polluters than passenger vehicles despite making up a much smaller portion of cars on U.S. roads. For this reason, the study’s authors say the U.S. should prioritize electrifying the commercial vehicles sector rather than just focusing on passenger vehicles.
PepsiCo- and KPMG-backed software logistics company Adiona Tech shared the Connected Thinking report on Tuesday, which suggests that last-mile combination trucks be electrified as soon as possible to help fight CO2 emissions. The company says that all urban deliveries of groceries, parcels, furniture and other goods should be performed by electric vehicles (EVs) by 2025.
“Commercial vehicles are a much bigger polluter than passenger cars and they are in desperate need of modernization,” Adiona writes in the report. “Large combination trucks are just 1 percent of vehicles on the road, but they produce 18 percent of vehicle emissions.”
The study compared Bureau of Transportation Statistics figures from 2019 to those of 2020 and 2021, looking at vehicle miles driven by passenger cars and trucks, along with their associated emissions. What it found was that emissions decreased significantly in 2020 and 2021, while truck miles and their associated emissions increased above 18 percent of road traffic emissions.
Sources: Connected Fleet data; BTS, fuel consumption by mode, additional combination truck stats, additional car stats, additional single-axle truck stats. Credit: Adiona Tech
The report included several key findings, notably including that the average fuel consumption of combination trucks is roughly 20 times higher than that of a passenger vehicle. The report also says that switching just five of these combination trucks to green alternatives — such as hydrogen fuel cells or lithium batteries — would be comparable to the effects of buying EVs for 100 households.
While the average truck drives about 22,930 miles annually, the report notes that large combination trucks travel an average of 59,929 miles in the same period, and single-unit trucks only average 12,278 miles annually.
According to data sourced from the Bureau of Transportation, light-duty vehicles with a short wheelbase have an average fuel consumption of 481 gallons per year, compared to 640 gallons consumed on average by light-duty vehicles with long wheelbases, and 1,639 gallons on average by single-unit, two-axle trucks with six tires or more. However, the data also shows that combination trucks consume an average of 9,909 gallons annually.
In a press release, Adiona Tech CEO Richard Savoie highlights the need to prioritize larger freight in the fight against carbon emissions, beginning with those that travel the most.
“America needs to aggressively decarbonize the biggest emitters on the road, large freight and delivery vehicles,” Savoie said in the release. “The US automotive industry is at a crossroads, but it needs to act now to electrify every car on the road. Doing so requires connected thinking and collective action. We cannot transform the national fleet of nearly 300 million vehicles overnight, so we need to make decisions that make the biggest difference, for the lowest effort first.”
The passenger vehicle sector has adopted EVs much more quickly than others, as several automakers have now followed Tesla’s lead in building fully electric vehicles. While electrifying every car is still an important goal, Savoie explains, it shouldn’t be the only one.
“Frankly, the data shows that consumer adoption of EVs should not be America’s number one priority,” Savoie said. “Electrifying fleets is by far the most efficient way to reduce vehicle emissions. Every battery we put in a combination truck counts for 20 households buying an EV, and businesses often have fleets of hundreds of vehicles.”
“We must prioritize the electrification of these vehicles that are on the road most, travel the longest distances, and are the least fuel-efficient,” Savoie added.
Several companies have begun piloting or at least stated plans to purchase electric last-mile delivery vehicles, including FedEx, Amazon, Walmart and more.
Adiona Tech backer PepsiCo is one of the first companies to have begun electrifying its semi-truck fleet after purchasing an initial batch of Tesla Semis last year. A recent event showed some serious range results for the Semi, and PepsiCo detailed last month how the truck was helping it reach its own sustainability goals.
You can read the full report from Adiona Tech here.
What are your thoughts? Let me know at zach@teslarati.com, find me on X at @zacharyvisconti, or send your tips to us at tips@teslarati.com.
A common misconception of anti-EV proponents is that the batteries used in the vehicles are detrimental to the environment and that they cause more waste than they are worth. But a look at Tesla’s battery recycling efforts last year shows the company is doing more than ever to recover materials and give portions of the cells a second life.
Tesla reported a significant milestone in its sustainability efforts last year, with battery recycling volumes rising 20% compared to 2024. According to the company’s 2025 Impact Report, Tesla recycled over 14,000 metric tons of battery material through a combination of in-house processing at its Gigafactories and collaborations with third-party recycling partners.
Tesla: “In 2025, we recycled over 14,000 metric tons of battery material through a combination of in-house processing and through our network of recycling partners.”
That’s equivalent to 46,000 long-range battery packs, a +20% increase from 2024. pic.twitter.com/TC3Nz7Kaqf
— Sawyer Merritt (@SawyerMerritt) July 7, 2026
This amount of recovered material is equivalent to the resources needed to produce approximately 46,000 long-range battery packs. The increase reflects growing operational scale as Tesla’s global vehicle fleet expands and more batteries reach end-of-life or manufacturing scrap becomes available for processing.
Tesla and Battery Recycling
Battery recycling forms a core part of Tesla’s circular economy strategy. The company designs its batteries for longevity, often exceeding 200,000 miles of driving, and prioritizes repairs, remanufacturing, and second-life applications before full recycling.
Once packs are decommissioned, Tesla ensures 100% are recycled with no materials sent to landfills. This approach recovers critical metals including lithium, nickel, cobalt, and copper, which can be refined and reused in new battery production.
Tesla has advanced hydrometallurgical recycling processes capable of achieving recovery rates up to 98% for key battery metals. These methods are more efficient and environmentally friendly than traditional pyrometallurgical techniques, reducing energy use and enabling higher-purity materials suitable for direct reintegration into battery manufacturing.
Tesla co-founder JB Straubel confirms Redwood’s battery recycling operations are already profitable
In-house capabilities are supplemented by a network of specialized partners, creating a robust system that handles both production scrap and end-of-life packs.
The environmental and economic benefits are substantial. Recycling reduces reliance on virgin mining, lowers the carbon footprint associated with raw material extraction and processing, and helps stabilize supply chains for critical minerals amid rising global EV demand. As millions of Tesla vehicles age, the volume of recyclable material is expected to grow significantly in the coming years.
This 20% year-over-year growth demonstrates the effectiveness of Tesla’s investments in recycling infrastructure and technology. It positions the company as a leader in addressing one of the automotive industry’s major sustainability challenges. Continued innovation in battery design for easier disassembly and higher recyclability will further enhance these efforts.
Overall, Tesla’s progress in 2025 highlights how scaling recycling operations supports both environmental goals and long-term business resilience in the transition to electric mobility. As the EV market matures, such closed-loop systems will become increasingly vital for sustainable growth.
Tesla has spent years trying to engineer its way out of the automotive paint shop, one of the most expensive, space-consuming, and environmentally costly steps in vehicle manufacturing. With the Cybercab, Tesla confirmed on X this week that a new reaction injection molding process will embed color directly into the panel itself during production.
“Our new reaction injection molding (RIM) process shrinks Cybercab paint cycles from hours to minutes. This cuts those parts’ manufacturing and supply chain emissions by 35% and eliminating 100% of paint volatile organic compounds (VOCs) emitted in traditional paint methods.” noted Tesla.
While the RIM process isn’t necessarily new and has existed since the 1960s, what makes Tesla’s application notable is how it is being used specifically for exterior body panels that traditionally required a separate paint process after forming.
Tesla’s RIM approach integrates the color directly into the panel material during the molding process itself. The pigment is part of the polymer mix injected into the mold, meaning the panel comes out of the mold already colored, with no separate paint application required. The clear coat or protective layer can be applied at the mold stage or through a much faster post-process than traditional multi-stage painting. Tesla claims this compresses what was a multi-hour paint cycle into minutes per panel.
Tesla’s obsession with killing the paint shop is one of the most consistent threads running through the company’s manufacturing philosophy going back years. As far back as 2018, Musk was trimming paint color options to simplify production, tweeting at the time: “Moving 2 of 7 Tesla colors off menu on Wednesday to simplify manufacturing.” Two years later, in a 2020 Automotive News interview, Musk laid out his broader vision, saying he believed Tesla factories could one day be 1,000 times more efficient than conventional plants, and pointing to the paint shop as one of the biggest sources of waste, cost, and complexity. The Cybertruck was the most extreme expression of that thinking. Tesla chose an unpainted stainless steel exterior partly because it would eliminate the need for a $200 million paint facility at Gigafactory Texas. The stainless approach proved harder and more expensive than anticipated, but the underlying ambition never changed. The Cybercab is what happens when that same ambition meets a manufacturing process that delivers on it.
Lifestyle
Tesla app update makes Robotaxi ownership make a lot more sense
Tesla’s app now shows a live indicator when your car is actively driving itself.
A recent Tesla app update, released last week (4.58.5), gives visibility on whether a vehicle is navigating in its semi-autonomous mode or being drive by a human driver. The updated app now displays a live “Self-Driving” indicator in bright blue text directly beneath the vehicle’s speed readout whenever Full Self-Driving is actively engaged, along with the signature glowing blue navigation path that FSD users see on the main touchscreen. It is a small visual update with meaningful implications for how Tesla owners monitor their vehicles remotely.
The feature was first spotted in the wild by X user Jordan Camina, who shared video of a Hardware 3 Model S displaying the new animation through the app while driving. That detail is significant because it confirms the update is not limited to newer HW4 vehicles. It works across hardware generations, and Tesla confirmed it will eventually support all vehicles regardless of chip platform once both the app and vehicle software are updated. The vehicle side requires software version 2026.20.6.1, which has reached nearly 40% of the fleet so far, as monitored by NotaTeslaApp.
The feature makes the most practical sense when viewed through the lens of Tesla’s expanding robotaxi operation. In a robotaxi context, the owner of a vehicle generating ride revenue has a direct financial and safety interest in knowing whether their car is operating under autonomous control at any given moment. The app’s new FSD indicator gives fleet owners exactly that visibility, the same way a logistics company monitors whether a delivery driver is following the planned route. It also carries implications for Tesla’s insurance model. Tesla’s own insurance product prices premiums in part based on FSD engagement rates, and real-time visibility into when FSD is active creates a feedback loop that could eventually tie directly into policy pricing. For individual owners who have opted their personal vehicles into the robotaxi network, the update effectively turns the Tesla app into a fleet management dashboard, one that tells you whether your car is earning money, whether it is driving itself to do it, and whether everything is operating the way it should from wherever you happen to be.
Tesla expands Robotaxi to Florida, marking its third state for autonomy
As Teslarati has reported, Tesla launched unsupervised robotaxi rides in Miami this summer, a milestone that makes a remote FSD status indicator significantly more practical than a cosmetic feature. When a vehicle is operating as a robotaxi without a driver present, the owner or fleet operator needs a reliable way to confirm autonomy is engaged. The app now provides exactly that.
As noted by NotATeslaApp, The update also arrived alongside a hint buried in the same app version that Tesla plans to use the cabin camera to verify driver identity before FSD can be activated. Pairing identity verification with a live autonomy status indicator points toward the infrastructure Tesla is building for a fleet of driverless vehicles that owners can monitor the way you would track a package delivery.
Tesla battery recycling efforts increased 20 percent last year
Tesla FSD is about to know your specific house and neighborhood better than any map
