Southampton-based Commercial Fuel Solutions has developed a ground-level AdBlue fill solution that is designed to enhance safety and ease of use for heavy machinery operators. The system eliminates the need for operators to climb ladders with 10-litre AdBlue cans to refill tanks mounted 2.5 metres off the ground. Instead, it allows AdBlue to be dispensed from ground level using a bowser.
Engineered for rugged environments
Specifically engineered for rugged environments such as quarries and construction sites, the system has already been installed on a range of Volvo excavators for Chepstow Plant, including the EC750, EC380, EC480 and EC400F models, and can also be fitted to the EC500F. It mounts onto the excavator, with a compact, vehicle-mounted pump and control panel that draws power from the machine’s own 12-volt electrical supply. A dry break interface and external control panel enable operators to refuel without accessing elevated or unstable areas. A built-in level switch provides automatic shut-off to prevent overfilling.
“No more balancing on ladders or hauling heavy cans. This solution puts operator safety first without compromising productivity,” said James Lovelock, senior design engineer at Commercial Fuel Solutions. “It’s powered directly from the machine, with automatic shut-off to prevent overfill, making it smart, safe and seamless.”
Matt Jennings, major account manager at SMT, said: “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.”
He added: “This complex project bridged across two generations of Volvo CE excavators, providing a solution tailored to each excavator size and available space within the machine’s toolbox compartment. This negates the need to climb on machine track pads and platforms whilst carrying heavy canisters of diesel exhaust fluid (DEF). Since release as a third-party option by SMT Great Britain, more customers have begun adopting this safety-enhancing solution.”
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.
Three years in development
The system has been three years in development – Chepstow Plant approached SMT in May 2022 to develop a one-man, ground-level AdBlue fill solution with auto shutoff. SMT in turn approached Commercial Fuel Solutions.
Chepstow Plant, safety, health, environment and quality (SHEQ) director Cath Pickett said: “This simple solution, eliminating foreseeable daily work at height events will make a significant difference to the safety of both Chepstow Plant operators 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.”
