Ground-Level AdBlue Filling System Transforms Excavator Safety
Commercial Fuel Solutions Ltd has unveiled a ground-breaking ground-level AdBlue® filling system, specifically engineered to enhance safety and streamline refuelling for heavy machinery operators.
Designed with rugged construction and quarry environments in mind, this solution eliminates a long-standing safety hazard, the need for operators to haul heavy 10-litre AdBlue cans up ladders to fill tanks located up to 2.5 metres above the ground.
With AdBlue tanks on large excavators reaching capacities of up to 70 litres and requiring regular top-ups, the risks associated with manual refuelling at height have been a persistent challenge. This innovation shifts the process to ground level, allowing operators to fill directly from a bowser with ease and precision.
Powered by the Machine, Designed for the Operator
The new system mounts directly onto the excavator, featuring a compact pump and control panel powered by the machine’s own 12-volt supply. It uses a durable dry break interface and external controls to ensure operators never need to access unstable or elevated areas.
A built-in, non-intrusive level switch automatically shuts off the flow once the tank is full, eliminating overfill risk. This feature not only improves safety but also prevents costly waste of Diesel Exhaust Fluid (DEF).
James Lovelock, Senior Design Engineer at Commercial Fuel Solutions, summed up the benefit: “No more balancing on ladders or hauling heavy cans. This solution puts operator safety first without compromising productivity. It’s powered directly from the machine, with automatic shut-off to prevent overfill, making it smart, safe, and seamless.”
Field-Tested in Tough Environments
This isn’t just a prototype. The system has already been deployed by SMT and Chepstow Plant across a variety of Volvo excavators, including the EC750, EC380, EC480, and EC400F, with compatibility for the EC500F. These installations are proving the concept in real-world, high-demand sites.
Matt Jennings, SMT Major Account Manager, emphasised the industry-wide safety gains: “The safety benefits of a ground level AdBlue fill solution for operatives in the Quarrying and Aggregate sector are a game changer! Thanks to the hard work and perseverance of the SMT team at the Machine Preparation Centre in Immingham, and Commercial Fuels Systems’ team the industry is a safer place to work.”
Bridging Excavator Generations
One of the most notable engineering challenges was creating a system that could work across two generations of Volvo CE excavators, each with varying toolbox layouts and space constraints. The result is a tailored solution that fits seamlessly into existing designs without compromising other functions.
Jennings added: “This negates the need to climb on machine track pads and platforms whilst carrying heavy canisters of DEF. Since release as a third-party option by SMT Great Britain, more customers have begun adopting this safety-enhancing solution.”
From Concept to Industry Standard
The project traces its roots to a request in May 2022 when Chepstow Plant approached SMT for a one-person, ground-level AdBlue fill system with auto shut-off. Ian Staples, SMT’s Product Compliance Officer, explained: “Recognising the complexity of this task, I was confident that Commercial Fuel Solutions would have the right expertise to partner with to deliver a safe and effective solution, supporting a safer way of working for Chepstow’s operators.”
For Chepstow Plant, the move represents a tangible step forward in safety culture. Cath Pickett, Safety, Health, Environment, and Quality (SHEQ) Director, highlighted its broader impact: “This simple solution, eliminating foreseeable daily work at height events will make a significant difference to the safety of both Chepstow Plant Operator and Client operators. Our ambition to take the lead on this will see real change filter down to the industry, making refuelling excavators safer for all.”
Retrofit Ready for Fleets
Beyond new builds, the system is available as a retrofit option for existing fleets, making it a practical upgrade for operators looking to align with best practice safety standards. This adaptability is key for industries where machinery has long service lives but must be brought up to modern compliance and safety expectations.
Commercial Fuel Solutions Ltd
Founded in Southampton in 2007, Commercial Fuel Solutions has become a leader in designing, manufacturing, and distributing fuel storage and transfer systems across sectors including rail, quarrying, marine, and motorsport. Their expertise extends to delivering bespoke solutions for high-profile clients such as Formula 1 teams, NASA, the US Air Force, the Royal Navy, Shell, and Jaguar Land Rover.
The company’s senior engineers hold influential positions in organisations like BSI, ISO, SFEM, PEIMF, and the UK Spill Association. They play a pivotal role in developing national technical guidance, including contributions to the Energy Institute & APEA’s Bluebook for filling station design and management.
Commercial Fuel Solutions is also the UK’s leading independent AdBlue supplier, servicing one in every 50 HGVs on UK roads.
Driving Safety and Sustainability Forward
This latest innovation reinforces Commercial Fuel Solutions’ commitment to both safety and sustainability. By reducing the risks associated with working at height, preventing DEF wastage, and ensuring more efficient refuelling, the system represents a practical advancement in heavy machinery operations.
With increasing emphasis on environmental compliance and operator welfare, solutions like these are set to become the norm rather than the exception. As adoption spreads, the ground-level AdBlue fill system could well be remembered as a small but vital step in reshaping site safety culture.
