Improved AdBlue infrastructure reduces operational downtime for major UK retailer
Published: 14 October 2024
The problem
As a leading provider of preventive maintenance services for many transport and logistics businesses across the UK, we understand the importance of AdBlue in keeping operations running smoothly. While working with a major UK retailer, we identified recurring breakdowns in their AdBlue infrastructure. These systems are critical in ensuring the reliable operation of diesel vehicles, so any disruption can lead to costly operational downtime.
The environmental damage of leaking AdBlue is also significant. If it reaches a watercourse, it can cause eutrophication, which occurs when water bodies receive too many nutrients. This leads to dense plant growth, which depletes oxygen levels and harms marine life.
A more robust and reliable AdBlue storage and dispensing solution was required.
The solution
To address this challenge, we designed a bespoke AdBlue system that prioritised resilience and reliability. The system incorporated several key features:
- Dual suction lines: Two suction lines connected to two pedestal pumps, fed by a submersible pumping unit, provide redundancy and minimise downtime in case of equipment failure.
- Emergency pumping unit: A third emergency pumping unit was integrated into the glass reinforced plastic (GRP) cabinet, with a direct feed from the tank, serving as a backup in the event of pedestal pump failure.
- OLE gauging system: An OLE gauging system with web portal access enables real-time monitoring and management of AdBlue levels.
- Independent consumer unit: A separate consumer unit ensures a stable and reliable power supply for the system.
The results
The new AdBlue system has significantly enhanced reliability and minimised downtime for our client. By incorporating redundancy and backup features, the system has reduced the risk of operational disruption from equipment failure, enabling better service for end customers and an environmentally safer infrastructure solution.
There have been tangible financial benefits too. We attended 10 callouts in the past year alone to repair AdBlue systems at our client’s sites, incurring around £10,000 in costs. Each incident has a negative impact on operations and profitability. The new system is expected to reduce the number of reactive callouts and associated costs, ultimately improving the overall efficiency and financial performance for our client.
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