EcoNavis receives U.S. Federal Grant by NFWF to study on integrated propulsion optimisation
Eco Boss Cap technology and cavitation comparison
EcoNavis Solutions has been selected by a U.S. Federal Government agency to lead a federally backed project aimed at demonstrating how integrated hydrodynamic optimisation can reduce fuel consumption and underwater radiated noise in offshore vessels and workboats operating in the Gulf of Mexico.
The award, valued at US$500,000, will support a full-scale retrofit and validation programme on a designated workboat, with the objective of establishing a repeatable framework for improving propulsion efficiency while addressing increasing scrutiny around underwater radiated noise.
Integrated approach to vessel performance
Rather than assessing individual technologies in isolation, the project will evaluate the combined impact of multiple energy-saving devices applied as an integrated system. The approach reflects a broader shift within the industry towards whole-vessel performance, particularly as operators face more stringent emissions and environmental rules along with rising fuel costs.
Dr Batuhan Aktas, Founder and CEO of EcoNavis Solutions, said the programme is designed to move beyond theoretical gains and deliver measurable operational results.
“This project allows us to validate, at full scale, how an integrated set of hydrodynamic technologies can improve propulsion efficiency and reduce underwater noise in real operating conditions,” he said. “The focus is not on a single device, but on how the entire propulsion train can be optimised and verified through data.”
Technical scope
The technical scope centres on the integration of a new flow-aligned twisted rudder, dubbed EcoVane; EcoNavis’ proprietary propeller hub Eco Boss Cap; and pressure-relieving modifications to the propeller blades. Each element targets a different source of hydrodynamic loss, from wake misalignment and drag at the rudder to vortex formation and cavitation at the propeller hub and blades.
“By addressing these effects collectively, the project is expected to deliver efficiency improvements of around five per cent, alongside a reduction in underwater radiated noise of more than three decibels,” said Dr Aktas.
The figures will be validated through controlled before-and-after sea trials, including direct measurement of shaft power and acoustic output.
Methodology and standards
The work will begin with computational modelling to establish a performance baseline for the selected vessel, followed by iterative design optimisation using vessel-specific flow analysis. Manufacturing, installation and full-scale trials will then be carried out, with all performance data collected and verified using recognised international standards, including ISO 15016 for fuel efficiency and ISO 17208-1 for underwater noise measurement.
EcoNavis will lead the hydrodynamic design and simulation work, supported by a consortium of propulsion specialists that include King Propulsion, CJR Propulsion and Oscar Propulsion.
Duncan Troy, the CEO of project partner Oscar Propulsion, the company behind the novel PressurePores technology where holes on the propeller blades mitigate cavitation noise, said: “The Gulf of Mexico has been identified as a key operating environment for the programme, given the high concentration of offshore support, harbour and crew transfer vessels, as well as increasing regulatory focus on both emissions and acoustic impact on marine ecosystems.
“The industry is under pressure from both fuel costs and regulation. What owners need are solutions that are not only technically effective, but commercially realistic. This project is about proving both.”
The project will also draw on established class approval and manufacturing processes to ensure that the solutions are scalable and suitable for wider fleet adoption. Beyond the demonstration vessel, the programme aims to generate a validated dataset that can support wider deployment across similar vessel classes.
EcoNavis said further updates, including details of the selected vessel and trial results, will be released as the project progresses.
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EcoNavis launches Eco Boss Cap Savings Estimator for shipowners
Home › News › EcoNavis launches Eco Boss Cap Savings Estimator for shipown…
EcoNavis has launched a new online savings calculator to help shipowners and operators make an initial assessment of the fuel-saving potential of an Eco Boss Cap retrofit.
Available on the EcoNavis website, the Eco Boss Cap Savings Estimator allows users to enter basic vessel information — ship type, dimensions, engine power and fuel price — to generate an indicative estimate of annual fuel and cost savings from the novel propeller hub. The tool is intended as a first-stage screening assessment before a full vessel-specific optimisation study.
Dr Batuhan Aktas, Founder and CEO of EcoNavis Solutions, said the calculator has been developed to help owners understand how relatively small propulsion efficiency improvements can translate into meaningful commercial benefits.
“Shipowners are facing a combination of fuel price volatility and rising regulatory pressure,” he said. “When bunker prices rise and carbon costs are added, even modest efficiency gains can have a meaningful commercial impact. The purpose of this calculator is to give owners and operators a practical first indication of where an Eco Boss Cap retrofit may justify a closer vessel-specific study.”
Indicative savings across vessel types
The Eco Boss Cap Savings Estimator draws on indicative modelling across a range of common vessel archetypes, including bulk carriers, tankers and container ships. Across these vessel types, indicative efficiency improvements are in the range of 2.7% to nearly 4%, depending on vessel size, propulsion characteristics and stern configuration.
For example:
- A 35,000 dwt handysize bulk carrier operating a 6,000 kW main engine for around 250 days per year could reduce annual fuel consumption by about 138 tonnes, equivalent to approximately US$142,968 per year at a VLSFO price of US$1,036/mt.
- A Panamax bulk carrier could reduce fuel consumption by about 266 tonnes per year, equivalent to US$275,576 per year on the same basis.
- For an 8,000 TEU container ship, annual fuel savings could exceed 1,100 tonnes, or US$1,139,600 per year.
(The VLSFO price used for these illustrations is the Ship & Bunker Global 20 Ports Average for 18 March 2026.)
Vessel-specific optimisation
Dr Aktas said the projections reflect EcoNavis’ design philosophy of vessel-specific hydrodynamic optimisation rather than generic appendage designs.
“Many retrofit devices are based on standard geometries that are applied across multiple ships,” he said. “Our approach is different. We analyse the flow conditions around each vessel’s stern using computational fluid dynamics and develop the boss cap specifically for that hull, propeller and rudder arrangement.”
Eco Boss Cap is a CFD-optimised propeller boss cap developed to reduce hub vortex formation and associated losses, improving propulsive efficiency and helping operators reduce fuel consumption and emissions. It is bespoke to the vessel and can typically be installed within a routine drydock work scope. Typical lead time from project start to delivery is around three to six months.
EcoNavis has already completed its first commercial installation on the 177 m general cargo vessel SFYC Araya, operated by Thailand-based Kaizen Ship Management. Early voyage monitoring from an initial installation indicates promising performance over 3% as reported by the fleet performance team.
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Kaizen returns to EcoNavis for second Eco Boss Cap retrofit after fuel savings verified
Home › News › Kaizen returns to EcoNavis for second Eco Boss Cap retrofit …
EcoNavis Solutions has completed retrofit installation of its Eco Boss Cap to a second vessel operated by Thailand-based Kaizen Ship Management. The successful installation marks the first repeat order for the energy-saving propeller technology since market introduction last year.
The latest retrofit, carried out on the 32,491 dwt bulk carrier YC Fortitude, follows the July 2025 installation on the 31,807 dwt general cargo ship SYFC Araya. After six months of operation the ship manager reported fuel savings in the 2.2% to 2.5% range.
The decision to install the novel propeller hub to a second vessel was based on measured performance improvements observed in service, alongside internal verification across different loading and operational profiles.
Operator endorsement
Kaizen Ship Management Managing Director Mr Kishen Dev Singh, who oversaw both installations, said the results provided sufficient evidence to proceed with further retrofits.
“SYFC Araya demonstrated consistent fuel savings. Based on what we have observed from the first installation, we were confident in proceeding with a second vessel and are evaluating further applications across the fleet.”
Both installations were completed during drydock at a Chinese yard, following successful factory acceptance testing. Eco Boss Cap casting and machining was carried out by EcoNavis’ partner Zhenjiang Supersoar Marine Propulsion, with the project taking three months to complete from order confirmation to installation.
Vessel-specific design
The Eco Boss Cap is designed to mitigate propeller hub vortex cavitation, a known source of propulsion and energy efficiency loss, through a patented configuration of internal chambers and flow passages that modify pressure distribution at the propeller hub.
Unlike conventional fin-based devices, each Eco Boss Cap is bespoke, designed for the individual vessel to which it will be installed using parametric modelling and computational fluid dynamics (CFD) optimisation. While the overall external geometry remains broadly consistent, flow characteristics are refined to maximise efficiency gains for each vessel’s specific profile.
For YC Fortitude’s 5,260 mm diameter four-blade fixed-pitch propeller, EcoNavis undertook a vessel-specific optimisation process to account for differences in propeller loading patterns and operating conditions compared with the first installation.
Technology validation
Dr Batuhan Aktas, Founder and CEO of EcoNavis Solutions, said the repeat order demonstrates both the reliability of the underlying hydrodynamic principles and the importance of vessel-specific optimisation.
“What is particularly significant is that the customer has observed measurable improvements within a relatively short operational period,” he said. “Detecting efficiency gains at this level typically requires extensive long-term data, so the fact that Kaizen has been able to verify performance and proceed with a second installation within months is a strong indicator of the technology’s effectiveness.”
Dr Aktas said that Kaizen Ship Management’s focus on acquiring and upgrading older vessels through targeted efficiency improvements provides a suitable platform for retrofit technologies such as the Eco Boss Cap. The company has indicated that it is considering further installations, with up to three additional vessels under evaluation as part of its ongoing fleet enhancement programme.
EcoNavis estimates that the Eco Boss Cap can deliver up to a 5% improvement in propeller efficiency depending on vessel type and operating conditions, with typical fuel savings in the 2% to 4% range and a return on investment achievable within a relatively short period.
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EcoNavis secures first commercial contract for Eco Boss Cap
Home › News › EcoNavis secures first commercial contract for Eco Boss Cap
EcoNavis Solutions has secured its first commercial contract for the novel Eco Boss Cap, a proprietary energy-saving propeller hub cap introduced to the market last year.
The fuel-saving, emissions-reducing hub will be retrofitted to a general cargo carrier operated by a Thailand-based ship manager. EcoNavis has received two purchase orders from the company, which is evaluating further installations across five more vessels.
Retrofit work to the 177 m long vessel’s 5 m diameter propeller is scheduled for mid-August at a Chinese shipyard, close to Shanghai. EcoNavis engineers will supervise the installation and early operation of the device, with sea trials expected shortly after the retrofit.
First full-scale deployment
When commissioned, the installation will mark the first full-scale deployment of the Eco Boss Cap, a conically shaped propeller hub featuring a patented arrangement of internal chambers and holes designed to reduce fuel consumption, emissions, and propeller-induced hub vortex cavitation.
Developed following extensive computational fluid dynamics (CFD) analysis and validation in one of Europe’s leading cavitation tunnel test facilities and towing tank tests, the Eco Boss Cap has demonstrated efficiency gains of up to 5% across all speed ranges.
Dr Batuhan Aktas, Founder and CEO of EcoNavis Solutions, and lead inventor of the technology, said the contract validates years of research, modelling and hydrodynamic testing.
“This is a significant milestone for EcoNavis as a serious technology partner to the global shipping industry. The ship operators’ interest came directly in response to our earlier work, which speaks volumes about both the industry need and the credibility of the energy efficiency results we’ve achieved,” he said.
Simple, effective design
Unlike traditional boss cap designs, which use fin appendages to redirect flow and can introduce turbulence, the Eco Boss Cap utilises an internal chamber and a series of precisely angled holes to manage water flow through pressure differential. This configuration eliminates the cavitation responsible for rudder erosion, underwater noise, and thrust losses, and avoids the torque penalties associated with fin-type designs.
With no blades, no fins, no rotating appendages, the Eco Boss Cap is easier to manufacture and install than most other energy-saving propeller hub caps currently on the market. Cast as a single piece and free of complex geometries, it can be installed during a standard drydock in under six hours.
“This cost-effective production means a lower upfront investment, with a payback time of less than a year for a 180 m handy-size bulk carrier burning about 25 tonnes of fuel per day,” said Aktas.
“This is not just a product launch. It’s the start of a new phase in ship efficiency,” said naval architect and EcoNavis Chief Operating Officer Amitavo Wye. “Eco Boss Cap is tailor-made for each vessel to deliver greater fuel savings over a wider operating envelope. Shipowners don’t want a generic solution; they want performance that works for their ships’ actual operating conditions.”
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Eco Boss Cap enters production following breakthrough CFD validation
Home › News › Eco Boss Cap enters production following breakthrough CFD va…
EcoNavis Solutions has begun production of its patented Eco Boss Cap propeller hub, marking the transformation of a university-led research project into an industry-ready fuel efficiency retrofit technology.
The first unit, destined for installation on a general cargo vessel, has been cast at a foundry in China using designs optimised entirely through computational fluid dynamics (CFD). It is currently undergoing final machining ahead of factory acceptance tests.
From research to production
The Eco Boss Cap eliminates the hub vortex cavitation that causes rudder erosion, vibration, and thrust loss in conventional propulsion systems. Unlike finned boss caps, which only function optimally at narrow speed ranges, the Eco Boss Cap features a smooth, conical design with internal chambers and strategically bored holes. This configuration uses fluid pressure differences to improve flow uniformity, reducing torque while increasing thrust across a wide range of operating conditions.
The innovation began as a research project at the University of Strathclyde, led by naval architect Dr Batuhan Aktas.
“We started by identifying the failure points of existing designs,” he said. “Fin-type caps tend to generate drag outside their designed speed. We wanted to create something simpler and smarter — a passive system that could dynamically adapt without complexity or cost.”
Initial CFD simulations showed performance gains of over 3% in efficiency and reduction in propeller hub vortex cavitation. But early prototypes revealed a critical problem: some hole placements actually reduced propeller efficiency. The team returned to first principles, iterating the design using advanced parametric optimisation tools.
The breakthrough came when engineers redesigned the internal chamber to align the suction flow with stagnation pressure points, allowing the cap to draw water through its core without impeding thrust. These insights led to successful trials at a European cavitation tunnel facility, where the final design outperformed other energy-saving caps.
Performance and cost advantage
Now under exclusive licence from the University of Strathclyde, the Eco Boss Cap is cast in a single piece, requires no moving parts, and can be installed in five to six hours during a normal drydocking.
“It costs about 50% less to manufacture than typical fin-based units and is expected to achieve a return on investment in under six months for mid-sized vessels,” said Amitavo Wye, EcoNavis’s Chief Operating Officer.
Early trials showed a 3.1% improvement in propeller efficiency, a 1.1% increase in thrust, a 2% reduction in torque, and a 10% decrease in rudder cavitation. Noise was also reduced by up to 3 dB, lowering the vessel’s underwater radiated noise footprint — a key issue for ESG compliance in sensitive marine environments.
“We’ve moved from lab to foundry in less than a year,” said Dr Aktas. “And with every unit, we’re refining not just our technology, but how fast and affordably we can deliver it.”
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New tests confirm Eco Boss Cap efficiency as pilot installation planned
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A second series of cavitation tests has confirmed that the Eco Boss Cap propeller hub improves fuel efficiency by up to 5% at full scale, as shipowners and propeller manufacturers express interest in the technology.
Full-scale CFD simulation of a ship operating at a design speed of 16.46 knots and turning a controllable pitch propeller with four different boss cap models found the Eco Boss Cap to be the more efficient solution, outperforming existing hubs by a factor of 2.5 or more.
According to the trials report, researchers concluded that propeller hub vortex cavitation was significantly eliminated by the holes in the Eco Boss Cap models, with vortex cavitation disappearing after interaction with the holes.
The test results mean that the simple-to-manufacture and install propeller hub can be retrofitted to large ocean-going ships as a way of contributing to shipowner ESG goals to reduce carbon emissions.
Eco Boss Cap inventor Dr Batuhan Aktas, a Chancellor’s Fellow in the Naval Architecture, Ocean and Marine Engineering Department at the University of Strathclyde, said: “Our approach to improving propeller efficiency is unique in both design and application. It diverges from traditional methods that typically use propeller hub fins to achieve similar outcomes. We are receiving a tremendous amount of industry interest.”
A key differentiating aspect of the Eco Boss Cap is the emphasis on cost-effectiveness and ease of manufacturing. Unlike conventional propeller boss cap fins (PBCF) which are complex and expensive to produce, the Eco Boss Cap offers a simpler and more economical solution without compromising on efficiency or performance.
Ship maintenance costs can also be reduced as propeller hub vortex cavitation is the primary source of rudder cavitation and damage. In addition, the Eco Boss Cap reduces underwater radiated noise and vibration levels, which impacts the migratory, mating and feeding habits of marine mammals.
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EcoNavis develops hydrodynamic energy-saving devices tailored to each vessel’s hull, propeller and rudder interaction. To assess whether Eco Boss Cap or an integrated optimisation package may be suitable for your fleet, contact the EcoNavis team.
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Eco Boss Cap validated as more efficient than existing propeller hub caps
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A revolutionary propeller hub vortex cavitation-eliminating boss cap has successfully completed validation tests at a hydrodynamic research centre in Sweden and will now undergo ship model basin trials to verify the efficiency gains on larger commercial and naval vessels.
Initial computational fluid dynamics (CFD) tests based on a typical twin-screw vessel with V-brackets and a 90 m coastal general cargo ship showed that the Eco Boss Cap increases propulsion efficiency by up to 5%, compared to conventional propeller boss caps. Tests also assessed the device against more advanced energy-efficient boss caps currently in operation, and found it to be at least 3% more efficient.
“Overall, compared to the propeller boss caps currently available, the Eco Boss Cap improved propeller efficiency by 3.1% and thrust by 1.1%, while reducing torque by 2%, rudder cavitation by 10%, and propeller-induced noise by 1–3 dB,” explained Dr Batuhan Aktas.
“The Eco Boss Cap eliminates completely propeller hub vortex cavitation, the main source of rudder erosion, and reduces associated propeller efficiency losses, which can be as much as 8%.
“Considering the investment levels required for other energy-saving devices currently in the market and the potential fuel savings, the Eco Boss Cap represents a significant advantage with a return on investment of less than six months,” he said.
How it works
The holes channelled into the Eco Boss Cap affect the high pressure in the hub vortex by redirecting the flow downstream. The resulting low-pressure swirl flows in the opposite direction to conventional hubs, behind the propeller blades, reducing propulsive drag, fuel consumption and maintenance costs.
“With shipowners grappling with new environmental legislation and emissions reporting rules, zero propeller hub vortex cavitation can help towards ESG, EEXI and CII goals, improve efficiency and reduce the costs associated with cavitation-induced rudder erosion.”
The Eco Boss Cap is reportedly less expensive than conventional propeller hub cap fins that incorporate small blades or fins to hydrodynamically deflect the water flow, as it is easier to cast and requires less material.
“What we have designed is a propeller boss cap that is 5% more efficient and costs 50% less to manufacture than current conventional propeller hubs. Considering the minimal investment required, this is a significant level of saving.”
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