A new electrochemical methodology is developed for coating ultra-low PtRu catalyst by depositing ZrO2/PANI/Melamine as a strong catalyst support for the electrode. Electrode position of PtRu alloy on the surface of pyrolysed ZrO2/PANI/ Melamine enhances the catalyst utilization (Pt: 78.4 mu g/cm(2), Ru: 0.57 mu g/cm(2)) in the methanol fuel cell. Pyrolysis of PANI and melamine on ZrO2 forms high porous graphene like structure which is identified by XRD/SEM/TEM. The surface composition and chemical oxidation states of Pt, Ru, Zr, C, N, and O are examined by XPS spectra. The DMFC performance has reached a peak power density of 68 mW/cm(2) in 5 M methanol concentration at 100 C with ultra-low catalyst loading in the anode. Comparing with commercial catalyst, 98% of PtRu usage has been reduced in this method which is first of kind ever reported. (c) 2016 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.