How does FuelActive work?
Unlike a standard fuel pickup pipe, the revolutionary FuelActive unit uses a dynamic floating pick-up that draws clean fuel from the top of the fuel level, thus avoiding the harmful contaminants that settle at the bottom of the fuel tank. The result is 92% cleaner fuel being delivered through the fuel system to the engine, reducing fuel consumption, CO₂ emissions and fuel-related breakdowns.
The Unavoidable Reality Inside the Fuel Tank
Diminishing Fuel Quality
Diesel fuel can degrade when stored, in transportation and inside equipment tanks.
The biggest operational problems usually come from water, microbial growth and solid particles which can lead to partially or completely blocked filters, create injector deposits and result in poor combustion.
The Impact of Lower Quality Fuel
Modern engines are highly efficient but also very sensitive. Even tiny particles or traces of water can disrupt combustion, damage injectors, clog filters, and block DPFs—causing breakdowns, expensive repairs, and costly downtime.
Degraded injectors produce a compromised spray pattern, preventing the fuel from atomising and combusting properly. Engine ECUs will detect and compensate by providing more fuel.
Poor combustion typically leads to three outcomes: reduced power, increased emissions, and increase fuel consumption.
Importance of Burning the Cleanest Fuel
Cleaner fuel protects sensitive engine components, ensuring the preservation of fuel economy, thereby maintaining OEM standard for longer.
FuelActive improves combustion by ensuring filters remain efficient, keeping injector spray patterns precise, which maximises energy from every drop.
This reduces fuel consumption and CO₂ emissions, while also protecting pumps, injectors, and filters from wear, corrosion, and blockages—minimising breakdowns and costly downtime.
FuelActive Benefits
Reduces Harmful Emissions
More efficient combustion results in 3% – 5% fewer CO₂ emissions. Every 1 litre of fuel saves 2.62kg of CO₂.
Improves Fuel Consumption
More efficient combustion results in 3% – 5% lower fuel consumption.
Reduces Cost of Ownership
Reduces Total Cost of Ownership through machine availability and reduced maintenance costs.
Reduces Downtime and Maintenance
Burning cleaner fuel avoids blocked fuel filters and damaged fuel pumps, which reduce engine downtime and maintenance costs.
Reduces Component Replacements
Burning cleaner fuel increases the life expectancy of fuel injectors, fuel pumps and fuel filters.
Reduces Fuel-related Breakdowns
Fuelactive not only reduces long term costs but also reduces everyday operating costs meaning the unit more than pays for itself across the life span of the unit.
Reduced Fuel Consumption for Lynch Plant Hire
"The machines with the FuelActive system averaged a 3.6% fuel saving. That’s equal to a £9,000 reduction in fuel over a year across the 10 trucks, taking 20 tonnes of CO2 out of the atmosphere."
James Barden | Head of Major Projects and Innovation | Lynch Plant Hire
Versatile Across All Sectors
FuelActive is a robust yet flexible solution in dealing with fuel contamination, reducing emissions and improving fuel efficiency which makes it suitable for a vast array of sectors.
Mining
Rail
Construction
Transportation
Pump
Power
FAQs
FuelActive is an award-winning fit-and-forget technology — once installed, it starts working the moment your equipment does. Thanks to its versatile design and the support of our dedicated engineering team, FuelActive fits most machine and vehicle types used across multiple sectors, helping you keep equipment running cleaner and longer.
What type of equipment can you fit FuelActive to?
Our knowledgeable and friendly team at FuelActive are always on hand to help you select the right FuelActive unit for your equipment. With an extensive product portfolio matched to the most popular equipment brands such as JCB, Caterpillar, Komatsu, DAF and models within a number of sectors, FuelActive can offer ‘off the shelf’ installation with short delivery times. For less popular models, confirming fit is easy and often only requires a quick survey of the equipment’s fuel tank to confirm specification.
Does FuelActive come with a factory warranty?
Yes, FuelActive comes with a 5-year factory warranty as standard.
What are the maintenance costs of FuelActive?
One of the best features of the FuelActive unit is that it requires no maintenance after installation.
How easy is FuelActive to install?
FuelActive requires minimal time to install, and it’s a non-intrusive process. Once the FuelActive unit is installed simply redirect the fuel feed to our patented unit.
Will FuelActive work at low fuel level or whilst my equipment is in motion?
Due to their relative density, contaminates such as water, sediment, rust and microbial growth (diesel bug) settle quickly and reside at the bottom of the fuel tank. In a standard fuel tank, contaminates are invariably drawn into the fuel system by a conventional narrow bore pick up pipe by process of suction (low pressure / high velocity).
In complete contrast, the dynamic float not only positions itself within the cleaner upper layers, but creates a unique flow dynamic by diffusing localised pressure, that even at low level, avoids contaminates such as water, by drawing the cleanest fuel available in the tank via a vent and not directly from the bottom of the fuel tank. Furthermore, the performance of FuelActive is unaffected by agitation (sloshing) of the fuel inside the fuel tank.
What fuel does FuelActive work with?
FuelActive works effectively in hydrocarbon fuels including diesel, petrol and HVO fuel. Using FuelActive delivers benefits anywhere where there is a threat of fuel contamination interrupting operations.
Is FuelActive ISO accredited?
FuelActive is manufactured to the highest standards. It is ISO 9001-accredited. Its steel and plastic components were chosen because they resist hydrocarbon fuels—diesel fuel, gasoline, kerosene and more. It has undergone thorough field tests and has been independently tested by a TS16949-registered filter company.
Run Clean. Drive Savings with FuelActive.
Install FuelActive today to take the next step on your sustainability journey — saving fuel, cutting CO₂ emissions, and protecting your engine from fuel-related breakdowns.
