Everllence has passed a cumulative milestone of 20 million operating hours across two generations of its medium-speed common-rail fuel injection systems.

The total combines service experience from the original CR1.6 platform, first introduced in 2004, and the newer CR2.2 generation that entered the market in 2024. Together, the systems have been deployed across more than 600 engines and around 5,500 cylinders, covering a wide range of applications and fuel types.

Michael Filous, senior vice president and head of PrimeServ Germany at Everllence, said: "20 million operating hours is a notable achievement that is born from 18 years of experience in the field involving over 600 engines, 5,500 cylinders, and across a broad range of applications and fuels. We recently brought production completely in-house, a key move that has greatly simplified the technical side of things for us."

CR2.2 is now replacing the earlier CR1.6 system on newbuild Everllence engine types, providing more precise control over injection timing and pressure to improve efficiency and emissions performance.

Compared with the previous generation, the company said CR2.2 delivers up to 38% higher rail pressure across all applications, reaching 2,200 bar, alongside more than 33% longer time-between-overhaul intervals for most components. The updated design also reduces the number of high-pressure connections by 35%, lowering leakage risk and improving serviceability.

Everllence said the platform has been developed to support a wide range of fuels, including alternative options such as hydrotreated vegetable oil and fatty acid methyl ester.

The CR2.2 system was first introduced on the company’s 49/60DF engine in September 2024. Everllence added that the first prototype of its 32/44CR engine is now being prepared for initial testing using the new common-rail generation.

Ahead of wider rollout, CR2.2 injectors were trialled for more than 12,000 operating hours on a 48/60CR engine, with the company reporting strong reliability results from the field test.