A.I.S.™ Additive Injection Systems
Automated additive dosing for high-volume fuel operations
Fuelcare designs, fabricates and tests A.I.S.™ systems at our UK engineering workshops. Each system is built for the continuous, automated injection of fuel additives into high-volume fuel streams, removing the variability and risk associated with manual dosing methods.
A.I.S.™ is deployed across terminals, forecourts and bunkering operations in marine, rail and industrial sectors, where accurate and consistent additive treatment is a core operational requirement.
Systems are compatible with a broad range of hydrocarbons, including aviation fuels, and are configured to meet site-specific flow rates and pressure parameters. Additive dispersal is metered and consistent throughout the fuel stream.
Optional IoT integration enables remote monitoring and control across single or multi-site operations, providing live data on dosing performance, tank levels and system status to support operational oversight and compliance reporting.
Why Choose A.I.S.™ Additive Injection Systems for Your Fuel Operations?
A.I.S.™ additive injection systems are compatible with all middle distillate fuels - diesel, gas oil, kerosene, petrol, heating oil, HVO, GTL and MGO - and are used in automated fuel additive injection across terminals, marine bunkering and rail depot operations.
Precision Dosing
A.I.S.™ maintains additive concentrations with a precision of ±1.5% of set point + ±0.1% of full-scale flow, ensuring consistent fuel quality and preventing under- or over-treatment. This reduces potential for fuel quality excursions and operational interruptions.
Optimised Additive Consumption
Automated, proportional dosing eliminates manual blending variances, directly reducing additive wastage and improving the cost-efficiency of fuel treatment programs.
Reduced Operational Risk
The automated system minimises manual intervention, mitigating the risk of human error in critical dosing processes.
Enhanced Safety & Compliance
Designed as closed systems, A.I.S.™ limits operator exposure to chemical additives, supporting COSHH compliance for closed system fuel dosing and reducing risk associated with manual additive handling.
Precision Engineered for Diverse Applications
Each A.I.S.™ additive injection system is custom-designed, fabricated and tested at our UK engineering facility before delivery, ensuring it meets the precise flow, pressure and chemical compatibility requirements of your fuel operation.
Compatible with all middle distillate fuels including diesel, gas oil, petrol, heating oil, HVO, GTL and MGO.
Site-specific system configuration
Each A.I.S.™ system is engineered to match specific operational requirements, including flow rates, pressure ratings, additive dosing ratios, and integration points within existing infrastructure.
Broad hydrocarbon fuel compatibility
Validated for use with middle distillate fuels including diesel, gas oil, petrol, heating oil, HVO, GTL, kerosene and MGO, ensuring compatibility across diverse industrial fuel additive dosing applications.
Industrial-grade UK manufacturing
Robust components are fabricated and assembled to industrial standards at Fuelcare's Shrewsbury facility. All systems undergo comprehensive pre-delivery testing to ensure performance and reliability.
Robust Design, Reliable Performance
Built for demanding marine and industrial environments, the A.I.S.™ Additive Injection System delivers accurate, durable, and dependable dosing for critical fuel treatment applications.
Designed for performance and ease of integration, the system accommodates a wide range of fuels, materials, and installation requirements.
Construction: Stainless Steel 304 or 316
Wetted Materials: PVC, PVDF, Stainless Steel
Seal Materials: EPDM, FKM, PTFE
Dosing Ratios / Pressures: From 0.0025 L/hr (Min 2 bar) to 200 L/hr (Max 4 bar)
Power: 100−240V±10% 50/60Hz
Additive Tank Size: Integrated 1−50 litres (adaptable to any size container)
Integrated tank level and spillage sensors: standard
Fuel Treated: Diesel, Gas Oil, MGO, Kerosene, Petrol
Approvals: CE Marked, PED Approved, ATEX Intrinsically Safe
Additional Approvals: Lloyds Approval (post-installation inspection), Pipework fittings approved to D.N.V. & A.B.S., B.V.
Sensors Included: Additive Tank level, Spillage, Door Opening
Stainless steel 304 or 316 construction for durability
Remote Monitoring & Control Options: Requires WiFi, Ethernet, or permanent GSM link (Calibration Pot)
From Assessment To Operation
A defined engineering process covering assessment, specification, installation and ongoing support to ensure each system is appropriate to site conditions, operational requirements and compliance standards.
System assessment and analysis
A detailed examination of your existing fuel infastructure, storage assets and operational parameters to identify potential vulnerabilities and treatment requirements.
Engineered solution proposal
We design and build a tailored solution based on a comprehensive analysis of your operational demands, fuel specifications and compliance requirements.
Turnkey installation and commissioning
Our technicians undertake all engineering work and ensure seamless system deployment and integration with minimal disruption to ongoing operations.
Continuous monitoring and support
Provision of real-time data, expert guidance and technical support to maintain fuel cleanliness, optimise engine performance and ensure regulatory adherence.
Real-Time IoT Monitoring of Fuel Infrastructure
Monitor tank condition, contamination levels, fuel quality and dosing activity across multiple fuel storage locations from a centralised dashboard.
The Fuelcare IoT dashboard provides real-time visibility of fuel system condition across all connected monitoring points. The system delivers data 24/7 across single-site installations, multi-location depot networks, and distributed fleet applications.
The dashboard monitors key fuel quality indicators and generates alerts when intervention is required. This enables proactive response to potential fuel system degradation.
Real-time tank contamination alerts and notifications
Automated dosing schedules with precision dose control
Fuel quality trend reports and historical data analysis
IoT-Enabled Monitoring and Control for A.I.S.™ Systems
Implement IoT technology to enable secure, automated additive dosing across multiple locations.
Remote Monitoring
Monitor and control dosing system status across multiple dispersed locations from a single interface - suitable for fleet operators, fuel terminals and multi-site logistics networks.
Real-time Data
Live data outputs include additive tank levels, fuel delivery volumes, line pressures and leak detection alerts - accessible via dashboard or data export.
Custom Software
Fuelcare-developed software built specifically for additive injection applications - configurable to site - specific dosing parameters, reporting formats and operational workflows.
Automated Alerts
Configurable email and SMS notifications triggered by critical system events including low additive levels, spillage detection, door open alerts and dosing anomalies.
API Integration
System data can be fed directly into corporate ERP, audit or compliance management platforms via API, supporting procurement reporting and regulatory documentation.
Automated Reordering
Low additive tank level thresholds can be configured to trigger automated reorder requests - reducing the risk of treatment gaps in continuous dosing operations.
Decades of Expertise and Collaboration
Fuelcare has over 40 years of experience in chemical dosing engineering and more than 15 years of specialist development in automated additive injection systems for fuel applications.
A.I.S.™ systems are in active deployment across fuel terminals, offshore platforms, marine operations and rail depots worldwide.
Fuelcare co-authored the Energy Institute guidance document on standardising additive injection for aviation fuel operations. The publication was prepared at the request of engine and airframe manufacturers to standardise the application systems used to inject and homogenously blend biocide into jet fuel during underwing pressure refuelling for aircraft maintenance.
EI Standard 1566 Injection of Biocide into Jet Fuel During Underwing Pressure Refuelling for Aircraft Maintenance
Fuelcare A.I.S.™ Additive Injection Systems FAQs
Find answers to frequently asked questions about Fuelcare's A.I.S.™ Additive Injection System and its applications.
An additive injection system automatically doses precise quantities of fuel additive in-line with fuel delivery - eliminating manual dosing errors, operator chemical exposure and inconsistent treatment. If your operation involves high fuel volumes, multiple delivery points, COSHH compliance requirements or the need for auditable dosing records, an automated injection system is strongly recommended over manual treatment.
Fuelcare's A.I.S.™ systems achieve ±1.5% dosing accuracy across their full operating range of 0.0025 to 200 litres per hour. This level of precision ensures consistent additive treatment at every delivery - eliminating the under-dosing that reduces product efficacy and the over-dosing that wastes product and increases cost.
All A.I.S.™ systems are CE Marked (EU Machinery Directive), PED approved (Pressure Equipment Directive), ATEX intrinsically safe certified (safe for use inexplosive fuel environments) and Lloyds approved for marine and offshore applications. Systems are manufactured from stainless steel 304/316 for long-term performance in demanding industrial environments.
Yes. Fuelcare's A.I.S.™ systems feature optional IoT connectivity for real-time monitoring of dosing rates, additive consumption and system performance via a secure cloud-based dashboard. Remote alerts can be configured for dosing anomalies, low additive levels or system faults. System data integrates with existing SCADA or fleet management platforms via API.
The A.I.S.™ system is designed to inject any of Fuelcare's liquid additives including CarbonClear™, FuelClear™ M15, OptiClear™ and CorroClear™ 100. It is compatible with all middle distillate fuels including diesel, gas oil, petrol, kerosene, heating oil and aviation fuels. Stainless steel 304/316 construction ensures compatibility with the full range of additive chemistries.
All systems are pre-tested in Fuelcare's UK workshops before delivery. Fuelcare's engineers handle complete installation from site assessment through to commissioning and handover. Most standard installations are completed within one to two days, depending on system complexity and site conditions.