The Best Prepaid Fuel Cards for US Fleets

Prepaid fuel cards are an excellent way for fleets to cap spending and cut down paperwork. Like a debit card or gift card, you load them up with funds and allow your drivers to spend on fuel within an allocated budget, leaving no surprises at the end of the month.

According to our research, the best prepaid fuel card is Shell’s Refillable Card. It can be used at over 15,000 US gas stations, has no monthly upfront cost, and you won’t incur the additional fees enforced by the likes of Brink, which will charge you for inactivity.

In this article, we’ll quickly compare our top prepaid fuel card recommendations. Further down the page, we also discuss alternatives to prepaid cards as part of our extensive buying guide on what the benefits of going prepaid are, what the different types of prepaid card look like and just how we test each card out.

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 Fuel 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 Fuel Card be improved?

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

For one, the card does not provide spending rebates or rewards/points, which may be a drawback for businesses seeking cashback on fuel purchases. Shell does have the Shell Fuel Rewards program, however this prepaid card can’t be used in conjunction with that scheme. It’s either one or the other if you are using its Refillable Card.

Elsewhere, Shell’s online account management system is relatively basic. It lacks the advanced expense tracking features that could assist businesses, especially those with lots of vehicles, in monitoring and analyzing fuel expenditures more effectively. Instead, it just shows your balance.

Lastly, while their network is extensive, the card is limited to Shell stations, unlike the near-universal acceptance of cards like Brink’s. And some states have fewer Shell stations than others, too.

This lacking is largely focused on the Midwest and Mountain West regions in states like North Dakota (15 Shell stations), South Dakota (13), Wyoming (16), Iowa (42), Kansas (21), and Nebraska (49). This can partly be explained by the lower population densities in these states, but it does mean if you are driving through these areas regularly, it may be harder to find a Shell station than in others like Texas (1,665 stations), California (1,386) or Florida (692).

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

Brink’s Prepaid Mastercard is a top option for use almost anywhere since drivers this Mastercard-backed card is accepted 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. Before you even get the card, Brink’s has a more extensive setup than the likes of Shell. The card requires verification of identity, business details, and address; without this verification, card usage is restricted, which may delay deployment if you need a gas card urgently.

Each account can have up to three cards, with a maximum of five accounts. This could limit its scalability for larger fleets since the maximum amount of fleet cards you could possibly have with these limits is 15 (three cards per account, for five different accounts). And even that could be inconvenient given you’ll need to have five separate user logins. With Shell, each account can have 30 cards, which should be plenty and less hassle in my view.

Unlike Shell’s refillable gift card, there’s a whole list of fees to be aware of with Brink’s prepaid card, too. The reason is you’re getting a lot more financial services in return for your investment. Still, I’d say Brink’s card is a lot more formal and lets you withdraw from ATMs, for instance. Here’s a snapshot of some of those fees.

You can find the entire list of Brink’s prepaid Mastercard fees here but, in short, there is some complexity to its fee structure. For instance, one fee of particular note is that you’ll receive a $5.95 inactivity fee if the card remains unused for 90 days. Similarly, balance inquiries at ATMs incur a $0.50 fee, though online inquiries are free. You’ll not be subject to per-purchase fees if you opt for its monthly plan, though you’ll be paying $9.95 per month for the pleasure.

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 a 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 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. The card lacks an online account management system, making it challenging for users to monitor balances or transaction histories conveniently. I would say Brink’s prepaid card is the best in this regard, as we detail above, offering the most advanced tracking of spending.

What I found even more irritating is that reloading the card requires purchasing a new one, as it is not reloadable, which may be inconvenient for truckers constantly refueling on the road or any other frequent drivers.

Furthermore, the card is only accepted at ARCO stations, which are primarily located on the West Coast and in the Midwest, limiting its usability for those who travel outside of these regions. That’s also true of Shell’s card though it has a wider range of locations across the whole of America, while Arco is more common near to US coastlines. With Brink’s card, you’ll be able to refuel almost anywhere, however, bettering them both if you need wide acceptance.

And since this is effectively a gift card, should the card be lost or stolen, the funds are not replaceable which is a risk, especially for more vulnerable drivers.

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

Buying Guide: Prepaid Fuel Cards

What are the advantages of prepaid gas cards?

• Less paperwork: With prepaid cards, you can avoid the hassle and sometimes extensive process of applying for a traditional credit card or even applying for a regular gas card. There are generally no credit checks, meaning business owners can activate and use these cards without much administrative burden, allowing them to spend on fuel without much delay.
• Easier budgeting: By going prepaid, you can set clear budgets for fuel expenses since the funds must be loaded onto the card before any purchases are made. This helps businesses avoid overspending and manage finances more effectively through this straightforward approach to controlling costs. Many cards come without ongoing fees, too.
• Digitize expense tracking: Usually, prepaid gas cards come with integrated digital tools that automatically track and categorize fuel expenditures. This reduces the risk of errors and potentially saves time on accounting going forward. Some more advanced software with sufficient analytical tools may even help a business optimize its spending patterns.
• Discounts on fuel: Many prepaid gas cards offer discounts at the pump. Saving money on fuel costs will always appeal to business fleet owners and these discounts will be a particularly fruitful way to cut expenses for those firms with high fuel consumption.
• Earn cashback: Alongside discounts, prepaid fuel cards often offer cashback on purchases. This can accumulate over time and provide another avenue of cost-cutting or reinvestment to a business.
• Other rewards: There are often other rewards from using prepaid fuel cards such as points that can be redeemed for goods or services or discounts on vehicle maintenance. Some bonuses are applied without regular card use, such as via referral incentives or through sign-up perks.

If this sounds like it’ll be the best option for you and your drivers, just request fuel card quotes directly through Expert Market.

The Different Types of Prepaid Fuel Cards Explained

When it comes to prepaid fuel card options, you’ll likely be choosing between two different types of fuel card:

• Prepaid gift cards – such as the Shell Refillable Card and ARCO PumpPASS
• Prepaid expenses management cards – such as Brink’s Prepaid Mastercard

The route you take depends on what you want from your card. Do you want to benefit from cash prices at specific gas stations? Would you like greater control over your expenses in general? Are you happy to pay a monthly subscription fee for greater spending control and insight, or would you rather go for something cheap and simple?

Let’s explore the key differences between these two types of card:

Types of Prepaid Fuel Cards: Prepaid Gas Gift Cards vs Expenses Management Cards

Alternatives to Prepaid Fuel Cards: Credit Fuel Cards

While prepaid fuel cards have many positives, a major potential drawback is that they require upfront funding. They generally have limited acceptance at certain gas stations or gas station networks too, which can be inconvenient for businesses operating in certain parts of the country. Plus, there are not always as lucrative rewards and benefits compared to credit-based fuel cards, such as loyalty points or cashback opportunities. And, of course, you are generally limited to fuel purchases only unlike other credit-based fuel cards or business credit cards which are accepted almost anywhere. 

An alternative option is purchasing a traditional fuel card. These cards act like credit cards and tend to be more widely accepted than prepaid fuel cards. They can help build your credit history when used responsibly too, and if you’re not phased by a little accounting, you’ll often get access to expense report creation tools that allow even greater control of your fuel finances.

A potential drawback of credit fuel cards is that savings are realized later on, rather than directly at the pump as with a prepaid card. Instead, cashback will be added to your account around one month after the payment period. Most of these cards require a monthly fee to be used too, while there is the risk of accumulating debt, potentially worsened by high interest rates should you not pay back the costs at the end of each month. All of this may not be preferable to businesses with tighter profit margins.

But for businesses that don’t mind waiting on their savings and can budget spending responsibly, credit fuel cards make a lot of sense for US fleets. Below you can click through our five favorite credit fuel card options or read about them in greater detail on our Best Fleet Fuel Cards page.

How We Rank Prepaid Fuel Cards