Operating a demand-response transit system leaves little room for error. For Chester County, Pennsylvania, that sentiment has shaped major fleet decisions behind Chesco Connect, the county’s door-to-door, shared-ride paratransit service. 

In December 2025, the Chester County Department of Community Transit began replacing its existing gasoline-powered Chesco Connect buses with new propane-powered vehicles. As the county worked to modernize its fleet while aligning with long-term climate and strategic goals, propane autogas emerged as a practical solution. 

One such solution that balances emission reduction, cost control, and the operational reliability needed for high-utilization community transit. 

A Transit System Defined by Constant Demand 

Unlike a fixed-route service, Chesco Connect operates a demand-response service designed to meet various mobility needs across the county, which requires responsiveness and vehicles that can withstand near-constant use.  

“This service model requires vehicles to remain in near-constant use throughout the day, with frequent stops, continuous route changes, and real-time scheduling driven by rider needs,” said Gene Suski, director of transportation for the Chester County Department of Community Transit. 

The scale of that demand is significant. According to the program’s annual report, Chesco Connect provided more than 141,000 trips during the 2024/2025 fiscal year, averaging approximately 556 riders per day and logging nearly 1.8 million service miles annually.  

The vehicles spend much of their time in stop-and-go conditions, often remaining in service for long hours with little downtime between trips. Given that level of utilization, fuel and operating costs quickly become a central concern. 

“Those realities directly shaped our fleet replacement strategy by prioritizing vehicles that can deliver reliable performance while reducing long-term fuel expenses,” Suski said. 

Why Propane Emerged as the Right Fit for Chester County 

As Chester County evaluated fuel options, propane autogas stood out as a solution that fit both operational needs and broader policy objectives, including lower fuel costs, reduced emissions, and relatively simple infrastructure requirements.  

“We believe that propane was the best choice because it costs less than gasoline and burns cleaner, producing fewer emissions,” Suski explained. “Propane requires less expensive infrastructure while delivering cleaner air benefits, making it well-suited for a high-volume paratransit system.” 

According to Chester County CEO David Byerman, the transition is a direct extension of previously adopted policy goals. When Chester County Commissioners approved the Climate Action Plan in late 2021, they set a vision that emphasized sustainability alongside fiscal responsibility. 

“These new vehicles will help realize the Strategic Plan’s goals of preserving environmental gains by reducing greenhouse gas emissions, while also saving taxpayer dollars,” Byerman said. 

From an industry perspective, propane’s appeal for community transit continues to grow. Todd Mouw, executive vice president, sales and marketing, at ROUSH CleanTech, explained how propane delivers emissions reductions while preserving the operating characteristics agencies expect. 

“[Propane] provides a reduction in harmful emissions such as nitrogen oxides (NOx) and offers a significant reduction in operating costs,” Mouw said. “This cost savings alone allows agencies the opportunity to provide an enhanced level of service for the communities they serve.” 

Supporting Stop-and-Go Operations and Long Service Days 

Demand-response transit places unique demands on vehicles. Frequent stops, extended idling, and constant cycling between acceleration and braking can strain powertrains and increase maintenance needs. Keeping vehicles available (and keeping downtime low) is essential. 

Currently, the county’s propane buses are refueled daily onsite, allowing them to return to service quickly without extended delays. From a maintenance perspective, propane vehicles have fit smoothly into existing Chesco Connect workflows. 

“They are maintained much like traditional gasoline vehicles, which helps keep maintenance simple and predictable,” Suski said. 

ROUSH CleanTech’s propane autogas systems are built on a gasoline-engine platform, removing many of the complex components associated with diesel engines.  

“Our propane technology starts on a base gasoline engine that we adapt to maximize the positive properties of propane,” Mouw said. “We eliminate all the increasing complexity of the diesel engine, such as turbos and additional after-treatment systems. This reduction in complexity improves uptime, reduces maintenance costs, and is much easier for technicians to support.” 

Plus, technicians working on one of ROUSH CleanTech’s vehicles will have access to all of the company’s tools and curriculum, such as web-based training to help technicians become comfortable with how ROUSH CleanTech integrates with the vehicle, onsite training at the agency location that is more in-depth and typically occurs post-deployment, or an immersive hands-on two-day course where technicians can put what they learn into practice. 

Aligning Fleet Decisions With Climate and Strategic Plans 

While operational performance and maintenance simplicity were key drivers, Chester County’s transition to propane was also shaped by its long-term policy goals. The county’s Climate Action Plan and Strategic Plan both emphasize sustainability, fiscal responsibility, and reliable service delivery. 

Those policy priorities are reinforced by propane’s measurable emissions benefits. According to Mouw, the propane-powered buses deployed will reduce air pollution from sulfur oxide, nitrogen oxide, and carbon dioxide, contributing to Chester County’s sustainability goals. 

At the same time, the county’s Strategic Plan prioritizes maintaining high-quality services without unnecessary financial burden, and Suski explained that propane is a practical way to achieve this. 

From a broader perspective, the deployment also reflects growing momentum nationwide. According to a 2024 study by the National Renewable Energy Laboratory, propane vehicles can achieve first-year fuel and maintenance savings of approximately $20,000 per vehicle, strengthening the financial case for agencies operating high-mileage fleets. 

Early Results and Long-Term Expectations 

Chesco Connect has already begun to see the transition take shape. As of late 2025, seven new propane buses have been placed into service, with another nine expected to join the fleet in February 2026. 

While the propane buses are still relatively new, early indicators point toward meaningful long-term savings. 

“We anticipate major cost advantages,” said Suski. “Expenses on fuel, fluids, and filters could be reduced by up to 50 percent compared to gas-powered vehicles, and our maintenance and downtime costs will drop as well. This is an exciting step into the future of transportation.”  

Looking ahead, the county is also planning to further strengthen its fueling strategy. 

“Chester County is in the process of developing its own propane fueling station to further control fuel costs, improve operational efficiency, and ensure reliable access for the Chesco Connect fleet,” Suski said. 

“Because propane is stored and dispensed as a liquid, we don’t need a large footprint to put in a fuel station,” Mouw explained. “In most cases, propane companies will put the infrastructure in for little or no cost in exchange for a multi-year fuel contract.” 

Lessons for Other Community Transit Agencies 

Chesco Connect currently operates 18 propane buses within its overall fleet of 74 vehicles, and the county plans to continue expanding its propane deployment in 2027. One of the most important lessons, Suski noted, is the value of a phased approach. 

“Transitioning to propane in phases helps ensure that daily service is not disrupted while the fleet continues to meet rider needs,” Suski said.  

Keeping vehicles available, easy to fuel, and simple to maintain is essential for demand-response service. For Suski, careful planning and a focus on total operating costs have allowed the county to make practical, long-term decisions while continuing to provide services. 

On the technology side, Mouw emphasized that familiarity with propane autogas is often underestimated.  

“From a day-to-day standpoint, the way propane buses operate is similar to gasoline — comparable range, same horsepower and torque, but with the added benefits of reducing harmful emissions and operating costs,” he said. “There is a reason propane is the third-most common engine fuel in the world. Our domestic supply is plentiful, it is clean, the infrastructure is easy to implement, and the buses operate seamlessly as compared to gasoline.” 

Those qualities have made propane not just an attractive alternative fuel, but a practical foundation for sustaining a high-demand transit system like Chesco Connect.