The Best Prepaid Fuel Cards for US Fleets in 2025

Prepaid fuel cards help fleets control gas and EV charging costs while reducing admin. Like gift cards, they’re preloaded with funds and limit spending to a set budget.

Our top pick is the Shell Refillable Card, accepted at 15,000+ stations in the US, with no monthly fees or inactivity charges. In this guide, we compare the best prepaid fuel cards and explore key alternatives. We also break down the benefits, types, and our testing process in our full buying guide below.

1. Shell Refillable Card: Best for Simplicity

The Shell Refillable Card is the simplest option for many businesses. Here’s why I think it could be a good option for you.

Why is the Shell Refillable Card worth considering?

Firstly, the Shell Refillable Card is a simple option for US fleet businesses because, unlike some competitors, including Brink’s, this card has zero monthly fees. That’s because it is essentially a refillable gift card, and the lack of fees allows users to allocate funds directly toward fuel expenses with no other associated costs (and keep topping it up, as and when required).

Users can load up to $300 onto the card via an online account, providing solid flexibility in managing fuel budgets so that you shouldn’t be left without any money, provided you top up the card.

Accepted at over 15,000 Shell stations across all 50 states, the card offers solid coverage and opportunities for refueling no matter where you are driving in the US, too. And with users allowed up to 30 cards per account, it’s a fairly convenient option for larger fleets, too, unlike the five-card limit per account with ARCO’s PumpPASS.

Additionally, most of its gas stations offer cash pricing, enabling users to benefit from the security of a PIN without incurring credit card charges. Plus, drivers can use their gift card to make non-fuel purchases too, such as auto supplies, food/snacks, car washes, and other items available at Shell locations nationwide.

How could the Shell Refillable Card be improved?

While the Shell Refillable Card offers several advantages, there are areas where it could increase its appeal:

• No spending rebates or rewards: The Shell Refillable Card doesn’t offer cashback, rewards, or points. While Shell has a separate Fuel Rewards program, it can’t be used with the Refillable Card.
• Basic account management: The online system lacks advanced expense tracking tools, making it harder for businesses with many vehicles to monitor fuel spending. It only shows your balance.
• Limited acceptance: The card can only be used at Shell stations, unlike cards with broader acceptance (e.g. Brink’s).
• Regional gaps in coverage: Shell station availability is also limited in some states, especially in the Midwest and Mountain West. Specifically, states like North Dakota (15 stations), South Dakota (13), and Wyoming (16) have fewer Shell stations. In contrast, Texas (1,665), California (1,386), and Florida (692) have a much higher concentration.

2. Brink’s Prepaid Mastercard: Best for Nationwide Coverage

Brink’s Prepaid Mastercard is a top option for use almost anywhere since drivers can use this Mastercard-backed product at most gas stations across the US. That’s because this card is designed for use by businesses of all kinds – not just fleets.

That does mean you’ll need to set up spending controls if you want your fleet to use it for fuel and little else, but it does provide the peace of mind that they can pay for fuel anywhere they need to. Here’s why else I think Brink’s is a good choice for your business.

Why is the Brink’s Prepaid Mastercard worth considering?

What stood out when I researched Brink’s Prepaid Mastercard is its huge flexibility. That includes the card being accepted at any location that accepts Debit Mastercard. This broad acceptance ensures that drivers can refuel at nearly any gas station, which is a significant advantage over brand-specific cards, like Shell’s.

I also enjoyed that the card features an intuitive expenses dashboard, enabling businesses to set up spending controls, monitor expenditures, and manage card usage effectively. This functionality allows for precise tracking of each driver’s spending, detailing amounts, categories, and locations. And of course, you can limit purchases to fuel only if you need to, as mentioned above.

Additionally, businesses spending $20,000 or more per month may qualify for a plan with no subscription fee, potentially reducing operational costs.

How could the Brink’s Prepaid Mastercard be improved?

Despite its advantages, the Brink’s Prepaid Mastercard has areas that could be bettered:

• Setup process: Brink’s requires identity, business details, and address verification before card use, which can delay deployment if you need a gas card quickly.
• Limited scalability: Each account allows up to three cards, with a maximum of five accounts. This limits fleet card numbers to 15 cards (three cards per account), which may be inconvenient with five separate logins. By comparison, Shell allows 30 cards per account, which could be less hassle.
• Fees: Unlike other options on this page, Brink’s prepaid card comes with various fees, including:
  • $5.95 inactivity fee after 90 days of non-use
  • $0.50 fee for ATM balance inquiries (free online)
  • $9.95 monthly fee if you choose the monthly plan (no per-purchase fees)

Brink’s offers additional services, such as ATM withdrawals, which contribute to this paid fee structure, adding flexibility compared to Shell’s simpler offering. You can find the entire list of Brink’s prepaid Mastercard fees here.

3. ARCO PumpPASS: Best for Cheap Fuel

The ARCO PumpPASS is a prepaid fuel card designed for cost savings, particularly for those who frequently refuel at ARCO stations. And since ARCO is recognized for offering competitively priced fuel, often lower than other major brands, this can be of major appeal. Here’s why I think the PumpPASS could appeal to you and your fleet.

Why is the ARCO PumpPASS worth considering?

The ARCO PumpPASS is a straightforward prepaid fuel card designed for ease of use, in my view. It allows users to load specific amounts – $10, $15, $20, $25, $50, or $100 – onto the card, which can then be used at participating ARCO stations.

This card helps users avoid the $0.35 fee associated with PIN debit card transactions at ARCO, offering a cost-effective alternative for purchasing fuel.

It costs nothing to order an ARCO prepaid gas card online, too. You only have to pay for postage, which is currently $2.95 from USPS First Class or $26.95 UPS Next Day.

How could the ARCO PumpPASS be improved?

While the ARCO PumpPASS offers simplicity and cost savings, it has certain limitations:

• No online account management: The ARCO PumpPASS lacks an account system for monitoring balances or transaction history. Brink’s prepaid card offers better tracking features in my view.
• No reload option: The card is not reloadable and requires purchase of a new one to continue refuelling. This can be inconvenient for drivers who frequently need to make fuel stops, such as truckers.
• Limited acceptance: The card is only accepted at ARCO stations, primarily located on the West Coast and in the Midwest, limiting its usability outside these regions. In contrast, Brink’s offers wider acceptance.
• Non-replaceable funds: As a gift card, the ARCO PumpPASS cannot replace funds if lost or stolen, posing a risk for vulnerable drivers.

To find out more about ARCO’s range of gas cards, check out our dedicated overview.

4. DAT One Fuel Card: Best for Efficiency

The DAT One Fuel Card is an engineered card for truckers and long-haul fleets seeking immediate fuel savings with no credit check. By offering discounts on fuel purchases and a handy mobile app for route planning, it streamlines refueling on the go.

Why is the DAT One Fuel Card worth considering?

The DAT One Fuel Card is ideal if you need a reliable, no-fee fuel option that delivers significant savings.

Unlike the Shell Refillable Card (accepted only at Shell stations) or the ARCO PumpPASS (limited to ARCO locations), the DAT One Fuel Card is accepted at nearly all gas stations nationwide. This universal acceptance can be a significant advantage to your drivers, as they can refuel regardless of their route.

According to DAT, users can save up to $1.73 per gallon at designated in-network stations. The card is reloadable via the DAT One mobile app, making it far more flexible than the ARCO PumpPASS, which requires purchasing a new card each time funds are depleted. This gives fleet operators dynamic control over fuel budgets.

Its mobile app not only helps track your balance and add funds instantly but also guides you to locate in-network stations, maximizing your per-gallon savings. This makes it especially useful for long-haul operations where every cent counts.

Similar to Brink’s card, DAT One can integrate with most fleet management platforms too, providing basic yet essential tools for monitoring fuel expenses without the extra fees often associated with Brink’s services.

How could the DAT One Fuel Card be improved?

While the DAT One Fuel Card is effective at cutting fuel costs, its appeal would be improved in a few ways. Here’s where we think it’s comparatively weak:

• Less extensive spend management tools: The card lacks robust spend management and detailed expense tracking. Brink’s Prepaid Mastercard offers a more extensive spending dashboard.
• Limited in-network discount locations: The card offers savings at in-network stations, but this premium discount network is smaller than Shell’s, at just over 2,200 stations. Most stations are along major trucking routes, so coverage is good in many areas, but I suggest checking if the stations near you are included.

Buying Guide: Prepaid Fuel Cards

If you are hearing about prepaid fuel cards for the first time, it’s worth explaining a little about them so you can fully understand what they can offer versus other forms of fuel cards.

How prepaid fuel cards work

Prepaid fuel cards operate similarly to gift cards. Instead of drawing funds from a credit line or linked bank account at the time of purchase, you preload the card with a fixed amount of money. As your drivers use the card to pay for fuel or other approved vehicle expenses, the transaction amount is immediately deducted from the available balance. Here’s a quick overview:

• Preloading funds: You choose an amount to load onto the card, and this becomes your fuel budget until you add more money.
• Usage: Drivers swipe or tap the card at participating fuel stations. Many cards now support contactless or mobile payments for added speed and convenience.
• Transaction tracking: Each purchase is recorded, and you receive detailed transaction reports to help monitor fuel spending.
• Controlled spending: Because purchases are limited to the preloaded balance, you maintain tight control over your fuel expenses.

How do prepaid fuel cards and regular fuel cards differ?

There are a few ways the prepaid approach to refueling can be beneficial (or potentially not), compared to regular fuel cards. Let’s go through them in this comparison table:

If this sounds like it’ll be the best option for you and your drivers, just request fuel card quotes directly through Expert Market. Likewise, you can read about all the different types of fuel cards on our explainer article.

How do you add credit to a prepaid fuel card?

One of the key advantages of prepaid fuel cards is how straightforward it is to add funds. In most cases, the process is designed for ease and speed:

• Online or app-based reloading: Most providers offer an online portal or a mobile app that lets you transfer funds into your fuel card quickly. You can use a debit or credit card, or directly link a bank account. Once the funds are added, the available balance updates in real time, so you know exactly how much is ready for use at every refuel.
• Automated top-ups: Additionally, some cards support automatic reloads based on preset thresholds, ensuring your drivers always have enough funds without manual intervention.
• In-person options: Depending on the provider, you may also have the option to add credit at designated locations (such as a fuel station kiosk) if online access is not available.

On the other hand, a potentially more inconvenient aspect of some prepaid fuel cards is that you need to purchase an entirely new card. These prepaid fuel cards are often called ‘gift cards’ and can’t be topped up with additional money when they run out.

That means you’ll need to wait for a new card to be delivered each time it runs out, although that could be as short as one or two days for no additional cost, depending on the provider. Still, it’s a potential issue if your team is regularly spending lots on fuel, and it means you must check with your prepaid card provider if you can top up your existing card to avoid this hassle.

Alternatives to Prepaid Fuel Cards: Credit Fuel Cards

As noted, credit fuel cards are the main alternative to prepaid fuel cards for businesses that prefer a revolving credit option. Here are the key points to consider:

• They do not require upfront funding. Instead, purchases draw on a credit line, which can be useful if cash flow is an issue (smaller businesses might find this particularly difficult).
• They are generally accepted at a wider range of gas stations and even for other business expenses, unlike many prepaid cards that are limited to fuel purchases.
• They can help build or improve your business credit history when used responsibly.
• Many credit fuel cards come with advanced expense report tools to help you track fuel spending more comprehensively.

On the downside, keep in mind that:

• Savings are realized later. Cashback or rewards are typically credited at the end of the payment period rather than instantly at the pump.
• There is often a monthly fee, and you run the risk of accumulating debt and interest if balances are not paid off in full.

These factors may not be ideal for businesses with tight profit margins.

For businesses that can manage delayed rewards and responsible credit usage, credit fuel cards can be a viable option. To explore your choices further, check out our favorite credit fuel card options on our Best Fleet Fuel Cards page.

How We Rank Prepaid Fuel Cards