When one of the UK’s largest retail logistics operators constructed its new flagship distribution centre, establishing a heavy-duty refuelling infrastructure was critical to maintaining non-stop fleet operations. Managing a high-volume Euro VI HGV fleet required a solution that combined bulk fuel capacity with safe, uncontaminated AdBlue® dispensing.
To meet the site’s high throughput requirements, fuel storage specialists Ledbury Welding & Engineering (LWE) manufactured and installed two 150,000-litre bulk diesel tanks. To complete the dual-fluid island setup, Tuffa Tanks engineered and supplied a bespoke, high-capacity bunded AdBlue® storage system.
The Challenge: Zero-Downtime Refuelling for Euro VI Fleets
Modern commercial vehicle fleets relying on Selective Catalytic Reduction (SCR) technology require a continuous supply of AdBlue® to strip harmful nitrogen oxides (NOx) from exhaust emissions and maintain Euro VI compliance.
At a major logistics hub handling hundreds of HGV movements daily, the storage setup faced three strict requirements:
Fluid Purity: Preventing fluid degradation or chemical contamination, which can damage sensitive SCR exhaust systems.
Operational Efficiency: Minimising turnaround times for drivers needing both diesel and AdBlue® top-ups.
Environmental Safeguards: Meeting strict secondary containment regulations while operating alongside 300,000 litres of bulk diesel.
The Technical Solution
Tuffa’s high-capacity plastic AdBlue® storage unit was specified and positioned directly at the centre of the main refuelling island, working in tandem with LWE’s steel diesel infrastructure.
Engineering & Material Specifications
UV-Stabilised Premium Polyethylene: Rotomoulded from non-corrosive, high-grade plastic to ensure AdBlue® remains completely pure and free from chemical leaching caused by reactive storage materials.
110% Integrally Bunded Protection: Designed with a double-skinned, secondary containment structure that holds a minimum of 110% of the inner tank capacity, exceeding standard UK environmental and pollution prevention guidelines.
Integrated Telemetry & FMS Connectivity: Equipped with direct output telemetry interfacing with the depot’s central Fuel Management System (FMS). This provides automated reordering alerts and real-time inventory monitoring for site managers.
Thermal & Weather Guarding: High-grade polymer construction shields the contents from direct UV light exposure and temperature fluctuations, preserving fluid integrity year-round.
Results & Operational Impact
| Performance Area | Key Outcome |
| Driver Throughput | Central island placement allows dual-fluid refuelling (diesel + AdBlue®) in a single stop, significantly reducing yard congestion. |
| Fleet Protection | Zero contamination incidents reported, safeguarding HGV SCR systems against costly downtime. |
| Site Compliance | Full alignment with UK oil storage and environmental containment regulations. |
| Inventory Control | FMS telemetry integration eliminated manual dip-sticking and reduced stockout risks to zero. |
“Large distribution hubs need total operational reliability. Placing our AdBlue® system right in the middle of the main refuelling island lets drivers handle dual-fluid top-ups in a single stop. It’s a great example of how steel and plastic storage options work together on modern transport sites.”
— Tuffa Tanks Technical Team
