Steve Whaley, Alternative Fuels Manager at Blue Bird, hosted a panel discussion at School Transportation News’ STN EXPO East 2025 to share customer success stories on replacing diesel buses with propane buses. The panel featured transportation leaders and alternative-fuel subject-matter experts with varied backgrounds, including:
Trey Studstill, Transportation Director
- Paulding County School District, Georgia
- 21,000 students transported daily
- 372 school bus fleet, 242 propane
Trey shared, “I’ve been doing this since I was 18 years old…and knew diesel school buses real well and had no intention of changing my fleet.” After a push from the district’s superintendent, Studstill made visits to Roush CleanTech to learn more about the product. “We [were] impressed by what we [saw] with the propane product. The Roush folks ran TCO calculations on our fleet…and we felt like it’d be a good fit and something that [could] save our district money.” The district began their propane journey in 2015 and has “never looked back.”
Dennis Ryan, Transportation Director
- North Penn School District, Pennsylvania
- 13,000 students transported daily
- 126 school bus fleet, 109 propane
North Penn School District switched to propane school buses for the potential cost savings and improved student behavior and test scores. Despite initial resistance, Dennis stated, “We got a lot of positive feedback from our student groups about it because of…not having fumes on a propane bus, the quieter ride. It helps with our drivers too in terms of having [better] student behaviors.” Now, “We’re striving to get our fleet to have those route buses at 100% propane because it works. It just flat out works.”
Joel Stutheit, Senior Project Manager of Autogas Development
Joel is a former transportation director from Washington state and now serves with the Propane Education & Research Council to drive the growth of propane Autogas in the transportation sector.
Why Propane Makes Sense
Cost Savings. Paulding County School Districtreports savings of about 43 cents per mile operating propane versus diesel. Dennis Ryan echoed this stating, “cost savings are second to none.” Joel referenced his time as Transportation Director, stating, “my cost analysis was 44 cents a mile for propane and almost 66 cents for diesel. So, major cost savings.“
2,623,000 miles driven * $0.43/mile savings in fuel costs = $1,127,890 in fuel cost savings alone over one year operating propane versus diesel powered school buses.
1,800,000 miles driven * $0.13/mile savings in fuel costs = $234,000 in fuel cost savings alone over one year operating propane versus diesel powered school buses.
Environmental advantages. The panelists cited a West Virginia University study which found propane to be 96% cleaner than the current [EPA] standard for particulate matter. Additionally, unlike diesel and gasoline, propane cannot contaminate water or ground sources if it escapes a vessel.
Positive driver and student experience. The majority of North Penn School District drivers have positive feedback, noting the quieter ride of propane buses makes it easier to manage student behavior. He mentioned studies indicating student test scores increased using alternative energy buses compared to new diesel buses. Paulding County School District took a proactive approach to driver education, ensuring drivers understood the safety and reliability of propane vehicles.
Addressing Infrastructure Concerns
Infrastructure Costs. Joel, drawing on his experience and current role, emphasized the importance of partnering with knowledgeable auto gas propane providers who understand the specific requirements for bus fueling. Setting up basic propane infrastructure can be less than $60,000 for districts that choose to purchase and own the equipment, which is significantly cheaper than EV systems. Many school districts, such as Paulding County, partner with their propane provider to receive equipment at no cost.
Infrastructure planning. Dennis Ryan discussed the upcoming relocation of their propane tank, highlighting the relative ease of moving propane infrastructure compared to other alternative fuel systems. Joel further elaborated on various infrastructure options, including permanent stations, mobile systems, and even bobtail fueling as a temporary solution. Dispensary systems can also be linked to existing fuel management systems for reporting. He stressed the importance of planning for future growth when setting up infrastructure, as well as working with your propane provider to create backup plans if needed.
Fuel Availability. Denali National Park in Alaska and various tribal community schools were mentioned as examples of entities operating propane school buses versus diesel, illustrating the wide availability of the fuel source. Steve shared the Department of Energy’s Alternative Fueling Station Locator, a website and app that shows public propane fueling locations across the US. The tool eases common concerns for public fueling availability, and makes it easier for transportation directors to route field trips.
Propane vs. Diesel
Maintenance and Operations. Trey stated that propane is more closely related to a gasoline type engine than diesel, eliminating the complexities and costs associated with diesel emissions systems like particulate filters and DEF systems. He estimated a substantial difference in oil change costs, around $30-$40 for propane versus $230-$240 for diesel. When asked about maintenance requirements, Trey answered, “in every aspect propane is a pro, not a con.”
Training and Support
Joel emphasized the importance of proper training for drivers and mechanics, highlighting the quality training provided by ROUSH CleanTech. The training includes web-based modules, on-site training, and Factory Technician Workshops, all offered free of cost to ensure districts have the resources needed for a smooth transition and ongoing operation of their propane fleets.
Look Ahead with Confidence
From substantial cost savings and environmental responsibility to positive impacts on drivers and students, propane is a smart and sustainable choice for school districts nationwide. As Joel aptly put it, “once you buy propane my feeling is you won’t go back.” The benefits were also echoed during an earlier panel, “The Right Bus for the Right Route: Managing Mixed Fleets,” along with insights on how to manage the transition to benefit students, drivers, school boards, and meet state and federal requirements.
If your district wants to explore the advantages of propane, learn more about Blue Bird’s propane school buses or contact your local Blue Bird dealer.