Fuel fraud has always been a thorn in the side of fleet operations, but in 2025, it’s no longer just about “off-hours fill-ups” or stolen cards. It’s evolved—smarter, harder to detect, and more costly than ever.
With the rise of advanced payment systems, telematics, and a mobile-first workforce, fraudsters have adapted quickly. What used to be a few bad actors siphoning gas is now a web of subtle manipulation, digital deception, and internal loopholes that can bleed a fleet dry without setting off alarms.
Here’s what you need to know about how fuel fraud is happening in 2025—and what you can do to protect your operation.
1. Phantom Fill-Ups Through Clone Cards
In 2025, fraudsters aren’t just stealing fuel cards—they’re cloning them digitally.
Thanks to skimmers and RFID intercepts, thieves can now replicate card data and make ghost transactions at legitimate pumps. These don’t trigger red flags because they appear to be normal fills at approved locations—often even during normal hours.
How to spot it:
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Identical card usage in two locations within minutes
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Charges just under transaction limits
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Repeated charges at the same location with no matching telematics data
What to do:
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Enable velocity checks and geolocation matching
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Require PIN verification tied to driver ID
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Leverage telematics to ensure vehicle presence aligns with transactions
2. Internal Fuel Fraud Masked as Legit Transactions
In many cases, the issue isn’t outside the organization—it’s within.
Technicians and drivers are getting more sophisticated, learning how to manipulate fill-ups without triggering alerts. Some are filling personal vehicles after fleet vehicles. Others are buddy-pumping—splitting one authorized transaction across multiple tanks.
New twist in 2025: Some use AI-generated receipts or even “ghost vehicles” in the telematics system to explain extra gallons.
How to detect:
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Gallons per tank exceed vehicle capacity
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Fill-ups don’t match mileage trends
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Fuel used without route activity logged
Mitigation tips:
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Lock fuel volumes to tank size
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Use geofencing and telematics cross-checking
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Audit pump times against actual vehicle activity
3. Mobile App Manipulation and Wallet Transfer Fraud
Many fuel programs now support mobile fueling via apps or digital wallets. While convenient, this opens the door for app-based fraud, where authorized users digitally “gift” fuel or wallet credit to unapproved users—often friends or family.
Some employees have even created dual profiles using personal emails to receive transferred fuel credits under the radar.
Warning signs:
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Frequent fuel wallet top-ups without corresponding usage
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Transactions occurring at unfamiliar times/places
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Inconsistent driver-to-card usage logs
Prevention tools:
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Enforce biometric authentication for mobile fueling
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Restrict digital wallet transfers
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Flag accounts with high transfer frequency
4. Telematics Tampering and Data Gaps
With telematics now central to fraud detection, some bad actors are learning how to disable, spoof, or interrupt these systems. Temporary disconnections or signal jamming can hide unauthorized trips or refueling stops, making fuel reconciliation near impossible.
Watch for:
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Blank GPS data during fill-ups
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Suspicious offline gaps in trip history
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Vehicles repeatedly going dark during fueling hours
Your defense:
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Use tamper alerts for telematics interruptions
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Cross-reference fuel logs with driver behavior and routing
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Schedule surprise audits during suspected problem windows
5. Fueling at Non-Network or Inflated Price Stations
In 2025, fuel fraud is also about strategic misuse, not just outright theft. Drivers may choose non-network stations with inflated prices, splitting kickbacks with shady vendors or racking up loyalty rewards.
Even worse? Some providers now mask surcharge-pricing behind a normal-looking transaction log, and your outdated reporting might miss it.
Identify it by:
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Above-market prices at out-of-network stops
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Patterns of “loyalty” to certain overpriced stations
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Discrepancies between expected and actual fuel costs
Prevent it by:
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Locking cards to a geofenced fuel network
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Using a provider that shows real pump prices, not just average data
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Reviewing station-by-station cost trends monthly
The Bottom Line: Fraud is Evolving—Your Strategy Should Too
Fuel fraud in 2025 isn’t a petty problem. It’s a serious threat to fleet profitability, often hiding in plain sight. But with the right mix of technology, policy, and awareness, fleet managers can stay one step ahead.
Whether it’s mobile wallet abuse, cloned card use, or creative internal misuse, the key is total visibility and intelligent control.
Fuel fraud is changing. Is your defense plan keeping up?
