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Powering tomorrow: How alternative fuels are driving the future of cleaner mobility

Alternative fuels are reshaping the road ahead, offering a greener replacement of traditional diesel and gasoline. They’re a genuine game-changer in the push for a more sustainable mobility – especially in industries – such as freight, aviation, and shipping – where going electric just isn’t practical. The path to more environmentally friendly mobility requires an open-minded, technology-neutral approach, blending various renewable fuels, biofuels, and innovative propulsion systems that meet the unique needs of industry and transportation. At MANN+HUMMEL, we're proud to play a vital role in this transition: our advanced filtration solutions help ensure cleaner fuels and reliable energy delivery every step of the way.

Why we need new fuels: It’s time to rethink what powers our cars and trucks

Cutting CO₂ emissions from transportation is at the top of every climate agenda. However, unless we make a bold move away from fossil fuels and embrace sustainable alternatives, those ambitious climate targets will stay out of reach. Enter e-fuels – synthetic fuels produced using renewable energy. When made from wind, water, or solar power, e-fuels can be nearly climate-neutral. Best of all, unlike electricity, they can easily be stored and shipped – even across continents – without losing any energy along the way. That’s why countries with plentiful sun and wind, such as Australia, Chile, and Morocco, are poised to become global hubs for clean fuel production.

But this transition isn’t just about transportation, it’s a critical challenge for the entire energy and industrial landscape. The keys to success?

  • Decarbonizing mobility with electrification and new fuels
  • Transforming our energy infrastructure to run on renewables
  • Teaming up globally to scale up sustainable technologies

Types and examples of alternative fuels: Where innovation hits the road

Every alternative fuel or powertrain comes with its own unique set of benefits and challenges. Some promise a lower carbon footprint; others make use of our existing infrastructure. However, biofuels and e-fuels rely on more sustainable raw materials, hydrogen needs entirely new logistics and refueling networks, and large-scale electric mobility calls for significant upgrades and investments in the electricity grid as well as battery technology. Ultimately, scaling these solutions depends on the right mix of government incentives, political will, public acceptance, affordability and ongoing technological innovation.

Think bioethanol and biodiesel – these fuels are made from renewable resources such as crops or even waste materials. Their big advantage? They can be used right away in today’s engines and at regular gas stations, often with little or no modification. But there’s a catch: the amount of available biomass is limited, so growth potential is capped.

When hydrogen is produced via electrolysis using renewable power, it really shines in heavy-duty and rail transport, thanks to its low-emission performance in fuel cells. However, successfully rolling it out on a large scale requires a whole new network of fueling stations and logistics. Europe, for example, still has a long way to go on that front. The good news? As renewable electricity gets cheaper and international cooperation in production and import increases, green hydrogen will become increasingly cost-effective. The goal: green hydrogen at market-competitive prices.

Synthetic fuels, or e-fuels, are made by combining captured CO₂ with more sustainable hydrogen to create a liquid energy source that’s remarkably similar to traditional fossil fuels. Thanks to their ‘drop-in’ capability, e-fuels can be used right away in existing combustion engines, pipelines, and gas stations but also in the aviation sector – with no retrofitting or expensive upgrades needed. That means instant compatibility for vehicles, refineries, and fueling stations, saving both resources and money. While the flexibility of e-fuels is a huge plus, current production volumes are still low and costs remain relatively high. Looking ahead, countries with abundant wind and solar energy are in a prime position to scale up e-fuel production and make it more affordable worldwide.

Battery-electric vehicles (BEVs) are leading the charge when it comes to clean, individual mobility. Their climate impact largely depends on how “green” the electricity powering them is – ideally, it’s 100 percent renewable. Charging networks are expanding fast, but full coverage is still a work in progress. Thanks to a rising number of models on the market, government incentives, and falling battery prices, EVs are becoming more affordable and practical than ever.

Technological hurdles and breakthroughs

Technological progress is the cornerstone of cleaner mobility. Nowhere is this more evident than in the ambitious field of e-fuels: around 50 projects worldwide 1 are already producing synthetic fuels, with another 20 currently in the pipeline. Together, these facilities could deliver about 5.9 million tons of e-fuels annually by 2030 2 – enough for an initial market entry, but still a long way from meeting the total demand of sectors like aviation and shipping in Germany alone. Limited production capacity remains one of the biggest challenges in this field right now.

At the same time, engine and battery technologies are advancing at an impressive pace. Today’s engines use significantly less fuel than those from the 1990s, and cutting-edge diesel engines are reaching record efficiency levels 3. Battery-electric vehicles are also reaping the rewards of innovation: solid-state batteries promise longer driving ranges and much shorter charging times.

  • Average gasoline consumption 4  has dropped from 8.8 to 7.4 liters per 100 km (1995–2023). The most efficient models 5  now use just 3.8 to 4.5 liters per 100 km.
  • Modern diesel engines can now achieve efficiency rates of up to 53 percent 6 under specified conditions.
  • In the battery world, solid-state batteries are seen as a game-changer, offering ranges of over 1,000 kilometers 7 and drastically reduced charging times – two key factors driving the future of electric mobility.

Alongside the ongoing development of battery technology and more efficient drive systems, researchers are increasingly turning their attention to new environmental and water protection challenges.

One current issue is managing PFAS (per- and polyfluoroalkyl substances) in fuel cell systems. These persistent chemicals can be released into water during operation, posing risks to the environment. To tackle this, MANN+HUMMEL is developing and testing special ion exchange resins designed to reduce PFAS in the water streams of fuel cells. Innovations like these are a key step towards minimizing environmental impact and ensuring fuel cell technology remains viable for the future.

Ultimately, the future of climate-friendly transportation will rely on a mix of innovative technologies. That’s why clear rules, supportive policies, and incentives for progress are more important than ever – to foster innovation, set standards, and keep the momentum going.

Policy and economic frameworks: Setting the course for alternative fuels

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Widespread adoption of alternative fuels hinges on clear, ambitious policy guidance – something the EU is actively delivering:

  • AFIR (Alternative Fuels Infrastructure Regulation) 8 : This regulation sets binding EU-wide targets for charging and refueling infrastructure: for example, fast-charging stations for cars every 60 km by 2025, and hydrogen refueling stations every 200 km by 2030. It covers road transport, shipping, and, partially, even aviation.
  • RED III (Renewable Energy Directive): By 2030, the transport sector must achieve at least a 14.5 percent reduction 9  in greenhouse gas emissions or reach a 29 percent share of renewable energy. RED III incentivizes the use of advanced biofuels, e-fuels, and the double-counting of renewable electricity, while limiting biofuels made from food and feed crops.
  • Incentives for consumers and industry include subsidies for vehicles running on alternative fuels, tax breaks, preferred parking and access, research and infrastructure grants, regulatory planning certainty, and certificates for sustainable production and CO₂ savings (such as those used in quota trading systems). 
  • International cooperation – through energy partnerships with countries like Chile, Namibia, and Australia – helps to secure future supplies of hydrogen and synthetic fuels. Initiatives such as “Mission Innovation” 10 are accelerating global investment in clean energy technologies.
  • Standards and certification schemes (for example, ISO 14687, ISO 15118, ISCC, REDcert) and harmonized lifecycle CO₂ accounting support market entry and global comparability of more sustainable fuels.

Looking ahead: Integrating alternative fuels into tomorrow’s mobility

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Alternative fuels are indispensable wherever electric mobility alone isn’t sufficient – such as in heavy-duty transport, aviation, and shipping. While vehicles running on these fuels are not yet completely climate-neutral, they do achieve a significantly improved CO₂ balance. Existing combustion engines can continue to be used more sustainably, avoiding the need for complex infrastructure changes.

Within the broader vision of smart cities, alternative fuels help support a nearly carbon-neutral, connected, and resilient mobility system. Low-emission municipal fleets, smart energy integration, interconnected mobility platforms, and the blending of transport and energy sectors all play a crucial role. Shared mobility models and sector coupling (integrating electricity, heating, mobility, and industry sectors to optimize the use of renewable energy) further boost flexibility and deliver additional climate benefits.

Possible future solutions include:

  • Complementing electric mobility with more sustainable fuels helps make the transition toward fully electric mobility smoother and reduces economic disruption.
  • Using synthetic and bio-based fuels for sectors that are hard to electrify, such as aviation, freight, and maritime transport.
  • Seamlessly integrating alternative fuels into connected, cross-sector mobility concepts.

MANN+HUMMEL leads the ways towards cleaner mobility

  • With 1.3 billion combustion vehicles on the road worldwide, the transport sector generated around 25 percent of global greenhouse gas emissions 11  in 2023. MANN-FILTER, our aftermarket brand, supports both conventional and alternative fuels, offering a broad range of fuel filters, especially for commercial vehicles.
  • Synthetic fuels can be aggressive on certain elastomer seals, sometimes extracting plasticizers and causing up to 10 percent shrinkage, which may lead to harmful leaks. MANN-FILTER tackles this challenge head-on with rigorously tested solutions.
  • By using innovations like lignin-impregnated filter media for more sustainable filters, we reduce the CO₂ footprint of our products by up to 5 percent and cut crude oil use by about 27 percent compared to traditional impregnation methods.

  • Easy-to-service transmission oil filters for e-axles and hybrid transmissions
  • Cathode air filters, ion exchange filters, broadband dampers, water separators, and efficient humidifiers for fuel cell systems
  • Pressure equalization and emergency degassing elements for battery systems
  • Coolant and air filters for the thermal management of battery systems
  • Protection of cooling circuits and cooling fans from contamination in fast-charging stations

 

Discover detailed specifications and further application insights on our dedicated MANN-FILTER product page: here

  • E-axles & hybrid transmissions: Modular transmission oil filters for suction and pressure side ensure efficient oil supply for transmission, electric motor, and battery. Integrated filter systems combine oil filter, reservoir, pump, sensors, and thermal management for maximum system efficiency and ease of maintenance thanks to replaceable filter elements.
  • For fuel cells: Cathode air filters protect against particles and harmful gases, while ion exchange filters reduce the electrical conductivity of the coolant. Humidifiers, broad band silencers, and cathode water separators ensure optimal operation and maximum efficiency; our humidifiers are developed and tested on innovative test benches to increase the service life and safety of fuel cell systems.
  • For battery systems: Venting units ensure optimal battery lifetime by providing permanent pressure equalization and emergency degassing at a defined overpressure.
  • For thermal management: Coolant particle filters and cooling air particle filters protect battery systems from contamination and overheating by efficiently removing harmful particles and debris.
  • For charging infrastructure: Specific filtration solutions protect cooling circuits and modern fast-charging stations from wear and other malfunctions. Whether air- or liquid-cooled, MANN+HUMMEL ensures the long-term operational reliability of high-performance charging systems.

We’re continually expanding our sustainability portfolio. With the new WK 1060/20 and WK 1060/40 biodiesel filter from MANN-FILTER, MANN+HUMMEL Brazil is introducing its first fuel filter system engineered specifically for the demands of biodiesel applications. This advanced, three-stage filtration system protects engines by effectively removing dirt and water, ensuring peak performance throughout the filter’s entire service life and minimizing maintenance needs. As a result, running on renewable fuels becomes even more efficient and reliable – another major step forward in sustainable mobility, thanks to MANN+HUMMEL.

We support safer, more sustainable mobility with highly effective filtration solutions for both traditional automotive engines and the latest e-mobility applications. Looking to upgrade or retrofit your vehicles and fleets for alternative fuels? Searching for state-of-the-art filters for cleaner fuels and optimized electrified drivetrains?

References

1, 2 https://foes.de/publikationen/2025/2025-02_Factsheet-eFuels.pdf
3 ,6 https://www.vdi-nachrichten.com/technik/automobil/weltrekord-dieselmotor-mit-ueber-53-wirkungsgrad/
4 https://www.umweltbundesamt.de/bild/durchschnittlicher-kraftstoffverbrauch-von-pkw
5 https://www.adac.de/rund-ums-fahrzeug/auto-kaufen-verkaufen/autokosten/geringster-verbrauch-benziner/
7 https://www.ingenieur.de/technik/fachbereiche/verkehr/feststoffbatterien-fuers-e-auto-so-realistisch-sind-1500-km/
8 https://data.consilium.europa.eu/doc/document/PE-25-2023-INIT/de/pdf
9 https://www.now-gmbh.de/wp-content/uploads/2024/04/NOW-Factsheet_REDIII.pdf
10 https://www.energieforschung.de/de/vernetzen/internationale-zusammenarbeit/mission-innovation
11 https://www.umweltbundesamt.de/presse/pressemitteilungen/finale-daten-fuer-2023-klimaschaedliche-emissionen#:~:text=Emissionen%20nach%20Treibhausgasen,um%2041%2C4%20Prozent%20gesunken