Dennis Eagle Case Study: A Cool Approach to Refuse Collection Vehicles

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Dennis Eagle Case Study: A Cool Approach to Refuse Collection Vehicles

Explore how a 25-year partnership with Dennis Eagle has delivered over 10,000 reliable cooling system s for Euro 6 refuse collection vehicles.

Customer Profile

Customer Name: Dennis Eagle

About Customer:With a heritage dating back to 1895, Dennis Eagle is one of the world’s leading manufacturers of refuse collection vehicles, delivering high-quality, safety-first vehicles to municipal and commercial operators worldwide.

Sector: Waste Management and Municipal Services

Location: United Kingdom

Application:Refuse Collection Vehicle

Products:

Grayson Cooler – Combustion Engine-Series (CP-3056-100)

Requirement

In 2012, Dennis Eagle began development of the Elite 6, a next-generation chassis designed to meet Euro 6 emissions standards and succeed the proven Elite 2 model.

Having supplied its cooling modules to the Elite 2 platform since 2005, Grayson was a trusted and established supplier of engine cooling systems for Dennis Eagle’s vehicles. The company was re-selected to develop a new bespoke cooling module for the Elite 6, which would be powered by the Volvo Penta MDE8 280HP and 320HP diesel engines.

The Elite 6’s under-cab configuration presented several design challenges, requiring a compact, efficient cooling system capable of maintaining stable engine temperatures under the demanding stop–start duty cycles typical of refuse collection operations.

Key performance requirements included: Maintaining optimal engine temperatures across all duty cycles, preventing hot air recirculation in the confined under-cab environment, ensuring the system’s mechanical drive was integrated with engine RPM for consistent thermal performance.

To validate performance, Dennis Eagle required comprehensive thermal testing to replicate extreme ambient conditions and high-load operating cycles representative of real-world refuse collection routes.

Our Solution

To meet these requirements, Grayson engineered a bespoke Euro 6 engine cooling module (CP-3056-100), designed specifically for the Volvo Penta MDE8 280HP and 320HP engine platform. This solution was built on experience gained from earlier Euro 5 development work, incorporating design refinements to meet stricter emissions standards and higher thermal loads.

The cooling pack construction consists of a radiator and charge air cooler (CAC) installed side by side, both manufactured from extruded aluminium tubes with formed dimpled fins and cast aluminium tanks for improved durability and heat transfer efficiency.

A mechanically driven viscous fan, operating at a 1:1.4 drive ratio from the engine pulley, ensured reliable airflow across the core during high-load and low-speed operation.

Initial thermal testing was carried out in September 2012 at (Millbrook International Test-centre), providing promising preliminary data. However, due to engine power limitations during the test, maximum-load conditions could not be replicated.

To complete validation, a further, comprehensive validation programme was conducted in collaboration with Volvo Penta’s test engineers at their facility in Lyon, France. Using a rolling dynamometer, a fully loaded 18,000 kg vehicle was tested under controlled 40°C ambient conditions, replicating real-world refuse collection cycles.

Performance was measured at both maximum power (2100 RPM) and peak torque (1600 RPM), using thermocouples and high-resolution data logging to monitor system stability. The results demonstrated that the Grayson cooling pack exceeded Volvo Penta’s performance targets.

The system comfortably maintained safe engine temperatures and surpassed the target of 40°C – a clear indicator of robust design and surplus thermal capacity.

These outcomes confirmed that the Grayson CP-3056-100 met and exceeded all Volvo Penta validation criteria for the MDE8 320HP engine platform.

Outcomes

Following successful thermal validation, Volvo Penta engineers confirmed that the system met all cooling requirements for the MDE8 280HP and 320HP engine and approved the Grayson cooling pack for Euro 6 applications.

Subsequent installation reviews at Dennis Eagle’s Warwick assembly plant verified the system’s fitment and integration in the vehicle architecture, completing the official sign-off process.

Since its introduction, this proven cooling solution has been adopted across Dennis Eagle’s entire Euro 6 fleet and has demonstrated exceptional durability in the field.

Chris Benton, Head of Purchasing and Supply Chain at Dennis Eagle, said: “Grayson has consistently delivered high-quality cooling solutions that meet the rigorous demands of our refuse collection vehicles, helping to ensure our customers’ fleets operate efficiently and safely. Grayson’s thermal management expertise and its team’s commitment to outstanding engineering, quality and reliability have made it a valued supplier. Achieving the 10,000-unit milestone and sustaining a partnership for over two decades underscores the strength and excellence of this collaboration.”

With more than 10,000 units produced to date, the project showcases Grayson’s ability to deliver validated, scalable thermal management systems that meet stringent regulatory and operational demands.

Key outcomes

10,000 units and counting

Over 10,000 cooling packs have been produced to date, supporting refuse collection vehicles operating globally, with more than 1,000 units manufactured in 2025 alone.

Low servicing and maintenance costs

The CP-3056-100 cooling systems have maintained an extremely low field failure rate, offering operators long service life, reduced downtime, and minimal maintenance requirements.

Long-term partnership

A 20-year collaboration between Grayson and Dennis Eagle built on consistent technical support and supply stability across vehicle upgrades and emissions cycles.

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