Exhaust Gas Recirculation system (EGR) has been used for years for NOx emissions control in commercial vehicle applications. Emissions limits are tighter with every regulation while durability requirements are increasing, so EGR systems manufacturers must be able to provide high performance and robust designs even with high thermal loads. Commercial vehicle market is characterized by lower production rates than passenger car programs, but same engine has multiple applications with totally different engine calibrations. In some cases it is necessary to design two or more EGR systems for an engine platform, with the consequent impact on cost and development timeline. The optimal design of and EGR system needs to take into consideration several topics related with performance and durability: efficiency and pressure drop, fouling, boiling, thermal fatigue, vibrations, pressure fatigue and corrosion among others. Furthermore, these designs must be cost effective and adaptive to different engine calibrations and duty cycles, which is a very complex process. The present work deals with technical solutions for solving the abovementioned issues based on the analysis of several engine specs and duty cycles from different commercial vehicle engines. The same solution can be used in different applications so with 4 EGR cooler designs it is possible to cover the spectrum of engines from 2.2l up to 15l.