CONCORD, N.C. – Expert panels presented by major school bus manufacturers at the Green Bus Summit centered on the theme of industry flexibility and resilience amid questions about the future of federal funding.
Blue Bird: The Right Bus for the Right Route: Managing Mixed Fleets
Luke Patrick, director of maintenance and training for the South Carolina Department of Education, oversees a fleet of 5,620 electric, propane, gasoline and diesel school buses. Electric school buses, he said, are purchased using government funding, operate on shorter metro routes, and are placed on routes where depot facilities already have power on site. Propane has been good for the state because of reduced maintenance costs and gasoline buses are used sparsely in more remote areas.
No matter the fuel, he said good working relationships are needed with districts so implementation goes smoothly.
Stephen Whaley, eastern alternative fuels manager for Blue Bird, reviewed the current powertrain energy options of diesel, gasoline, propane and electric as well as their acquisition price tags and approximate range. Most school bus down time results from diesel aftertreatment requirements, he reminded.
Over 2,000 Blue Bird electric school buses are deployed in 42 U.S. states and four Canadian provinces, shared Brad Beauchamp, the OEM’s EV product segment leader. “We’re continuing to evolve this product to give you better range,” he confirmed.
He added that a DC fast charge solution is better than Level 2 AC, but a yard planning option is best for long-term fleet electrification goals.
Tom Hopkins, business development manager for drivetrain manufacturer and longtime Blue Bird propane partner ROUSH CleanTech, reviewed the cost savings that buses running on safe, clean, domestically produced, affordable propane Autogas produce compared to diesel.
Whaley reviewed the easy-to-implement and scalable propane infrastructure. While alternative fuel tax credits are generally available, he said he’s not sure they will be renewed by Congress. Even without those incentives, those fueling and maintenance cost savings add up to a savings over diesel, he added.
CowFartBus: A Zero Carbon Alternative for Existing Diesel Buses
Robert Friedman, managing director for CowFartBus powered by Demi Diesel Displacer and Neufuel, explained the company’s mission of converting existing diesel school buses to run on one tank of renewable natural gas (RNG) and another of diesel. There’s no compromise in vehicle or fleet logistics and no need to buy new buses, he said.
He added that Renewable natural gas fueling pressure is lower than regular CNG, so the affordable filling station is simply 2-feet by 2-feet. The bus can still run solely on diesel, if needed. He explained that 26 buses can be converted to CowFartBus for the price of one new electric school bus, resulting in optimal sustainability.
Friedman confirmed the refitted buses’ durability in harsh altitude and weather conditions, as they are being used in multiple districts including Eagle County School District in Colorado, which has six of these buses and is adding eight more with plans to convert the whole fleet.
“We’ve been so happy with this system and see the promise in it,” said Joe Reen, the district’s executive director of operations.
He relayed that the budget is tight with a driver shortage necessitating that 20 buses each run about 100 miles a day in rapidly changing altitude and weather conditions. But the buses do not experience power loss. Even 30-year bus drivers like them, he shared.
Some community members desire greater environmental sustainability while others want cost savings, and CowFartBus hits both those points, he said. It was a good alternative for his district, Reen added, since electric doesn’t work for their region.
“There’s not a single silver bullet,” Friedman agreed.
Luke Patrick, director of maintenance and training for the South Carolina Department of Education, oversees transportation of 170,000 students a day on 5,620 buses with an average route length of 70 miles, consuming 11 million gallons of fuel per year. He said a big draw for the state was that the RNG complements diesel but doesn’t replace it. Charleston School District near the coast is currently running two CowFartBuses, and Patrick said he is looking to acquire 50 more.
Both districts reported high satisfaction levels from the drivers, which is good news for driver retention efforts.
Friedman recommended converting older buses if manufacturer warranty is a concern but confirmed that CowFartBus covers the warranty on buses they convert. “Our longest running bus has 800,000 miles on it,” CowFartBus Director Sam Johnson added.
Related: (STN Podcast E252) Onsite at STN EXPO East in Charlotte: School Bus Technology Interviews
Related: Gallery: Ride and Drive at Charlotte Motor Speedway
Related: Gallery: Second Day of STN EXPO East Green Bus, Technology Sessions
Related: WATCH: STN EXPO East 2025
Related: The State of Green School Buses
Related: Propane ‘Easy Button’ to Replace Diesel School Buses, STN EXPO Panel Claims
Maintenance Tools from IC Bus
Regional Sales Manager Marc Trucby reviewed updated aspects of OnCommand Connection, a platform that comes standard on all IC buses since 2023 and collects vehicle health data through factory or aftermarket telematics devices.
He also shared information about a prospecting tool that helps districts find green bus funding and a partnership with Sourcewell for streamlining the RFP and bid process.
Gregory Baze, IC’s national account manager for parts, discussed the Repairlink solution that is designed to provide school bus repair shops with 24/7 online parts ordering. It gives technicians an easy way to connect with dealers and suppliers for fast, accurate parts sourcing and communications.
The new addition helps school bus technicians more efficiently search for and reorder the parts they need from a larger inventory selection, he explained. A VIN-based catalog, saved shopping carts, price comparisons and coupon discounts are additional benefits.
“You are essentially your own dealer looking up your parts,” he said.
Attendees asked about various aspects of placing orders and Baze provided details on how school bus mechanics and technicians can do so.
For security purposes, districts can only enter information for school buses they own and operate and save the data into the system so they can shop by bus for any specific parts it needs. Baze confirmed that contracted buses are also eligible for Repairlink and that customer service can work with districts to complete this.
“We do a lot beyond buses,” Baze concluded.
Thomas Built Buses: ICE – The Future Outlook for Traditional & Alternate Fuels in School Buses
Thomas Built Buses General Sales Manager Jim Crowcroft stated that diesel is still very much a part of the school bus landscape.
Luke Patrick, director of maintenance and training for the South Carolina Department of Education, shared that his fleet is over 80 percent diesel due to needed range. It also contains over 500 propane buses, which he said have about half the range but lower operating costs and fewer maintenance issues. While his electric school buses (ESBs) come with range concerns, he said that district collaboration is key to improvement.
Amidst upheavals in the U.S. Environmental Protection Agency and federal government funding, the panelists reiterated OEM commitment to both ICE and electric options to serve customer needs.
“It’s our job to learn what your goals are and support you though it, whether you’re looking at diesel or other alternative fuels,” said Kelly Rivera, general manager for school bus dealer Carolina Thomas.
Daoud Chaaya, vice president of sales, aftermarket and marketing for Thomas, said he sees diesel and octane as a bridge to greater sustainability until ESB Total Cost of Ownership and price parity are achieved. Cummins’ Francisco Lagunas, the North America bus segment general manager, noted that the company’s octane engine will be available by January 2026 and the B7.2 diesel engine by January 2027.
Chaaya said that despite uncertainty in government funding, several U.S. states indicate a firm commitment to school bus electrification, plus both the knowledge and support networks are only growing stronger.
“By the end of the year a lot more clarity will come around,” he predicted.
Rivera pointed out that diesel buses are now being manufactured with cleaner engines by default. Lagunas added that manufacturing cleaner diesel buses increases their price while ESB manufacturing is becoming cheaper as that product improves.
“We need to diversify,” he said of OEMs.
Patrick spoke to the importance of proactive training when rolling out school buses with a different fuel or energy source than technicians are used to.
Chaaya confirmed that dealers and school districts are all included in the collaborative decision on what an OEM manufactures. “We want to thrive, not just survive in this ecosystem,” he said.
The panelists agreed that clarity, communication and speedy dialogue with the EPA is helpful for unified, stable OEM decisions and concrete answers to districts. “In absence of decision making, rumors and anxiety run wild,” Chaaya commented.
The speakers also expressed optimism for the future as student transporters are a resilient group. “It’s a really exciting time to be in student transportation as there are lots of products out there to meet your challenges,” Rivera concluded.
