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  • Vehicles
    • Tyre Safety
      • Introduction to Tyre Safety
      • The Different Machines And Their Applications
      • Tyre Use
      • Factors affecting tyre wear life
      • Machine Inspection
      • Tyre Inspection
      • Mounting & Demounting Tyres
      • Tyre Inflation
      • Twinning Tyres
      • Ballasting the Tyres
      • Regrooving Tyres
      • Tyre Repairs
      • Tyre Retreading
      • Tyre Handling and Storage
      • Tyre Workshops
      • Glossary
      • Tyre safety, Fires and Explosions in Mines
      • Minimising Tyre Fires and Explosions at our Mines
    • Safe Working/Driving Conditions at Mines
    • Transportation of Dangerous Goods
      • Behaviour Based Safety and Accidents
      • Transportation of Chemicals and AARTO
      • Awareness of Chemicals in Transit
      • Steps to Transport Dangerous Goods Safely
    • Traffic Calming
    • 4×4 Off-Road Driving
      • 4×4 Off-Road Driving Techniques
      • 4×4 Water Crossings
      • 4×4 Driving Hills & Rocky Surfaces
      • 4×4 Driving with Mud Tyres and Mud Driving
      • 4×4 Sand Driving Safety
      • Tools and Spare Parts for Safe 4×4 Driving
      • 4×4 Jacking & Snatch Recovery
      • 4×4 Terrain Knowledge
      • 4×4 Off-Road Driving and Conservation
      • 4×4 Winter Driving
      • 4×4 Driving and Usage of Recovery Straps
      • 4X4 Winch Guide
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Home General

Machinery maintenance and the hidden cost of fuel adulteration

July 1, 2025
in General
Machinery maintenance and the hidden cost of fuel adulteration
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Fuel adulteration remains one of the most insidious threats to industrial machinery, safety, and environmental compliance across multiple sectors. Craig FitzGerald, Chief Executive Officer of ISO-Reliability Partners, discusses how this widespread issue undermines not only mechanical performance and operational safety but also poses significant legal and financial risks.

“Adulterated fuel is not just a matter of poor performance; it is a direct threat to equipment integrity, worker safety, and environmental sustainability,” says FitzGerald. “The problem is far more prevalent than many realise, and the consequences are escalating.”

 

Quality Concerns

At the heart of the issue is the adulteration of diesel with substances such as illuminating paraffin (IP), used transformer oil, and gear oils. These agents significantly degrade fuel quality. “IP, for instance, drastically reduces diesel’s lubricity, which is essential for the protection of high-pressure fuel injection systems. Without proper lubrication, you are essentially guaranteeing elevated costs, premature wear and mechanical failure,” explains FitzGerald.

In addition, adulteration alters the fuel’s viscosity and density, directly affecting combustion efficiency and engine output. The result is increased maintenance frequency, unexpected breakdowns, and ultimately, far higher operational costs.

“We are seeing cases where seemingly minor dilution leads to major engine damage, simply because the physical and chemical properties of the fuel are no longer within operational parameters,” adds FitzGerald.

 

Safety Risks and Invisible Hazards

The safety implications extend well beyond engine wear. Used transformer oil, a common adulterant, often contains polychlorinated biphenyls (PCBs), a class of highly toxic chemicals strictly regulated under the Basel Convention.

“The combustion of PCBs in engines produces extremely harmful by-products, including hydrogen chloride and dioxins, many of which are carcinogenic and mutagenic,” notes FitzGerald. “When you are running adulterated fuel, you are creating chemical hazards that affect both operators and the broader environment.”

Mechanical reliability is also compromised. Poor fuel quality can cause diesel engines to fail under load, potentially creating hazardous conditions, particularly in heavy industrial or transport environments.

 

Environmental and Economic Fallout

Fuel adulteration does not just harm equipment and people, it undermines environmental protections and public finances. “This practice allows for the illegal disposal of hazardous industrial oils, leading to long-term soil, air, and groundwater contamination,” says FitzGerald. “It is a form of environmental abuse hiding in plain sight.”

Moreover, the economic consequences are staggering. FitzGerald highlights that losses to the South African fiscus from fuel adulteration and associated tax evasion are estimated to exceed R3.6 billion annually. “These are funds that could otherwise support environmental enforcement, infrastructure, and community development,” he says.

 

Proactive Industrial Measures

FitzGerald advocates for a combination of advanced technology and sound procurement practices to combat adulteration. Real-time sensor technology like the Yateks® Africa FuelTrust system allows for real-time on-site detection of critical fuel parameters, including density, viscosity, dielectric constant, which flags contaminants such as paraffin and PCBs, as well as moisture content and temperature. These sensors are particularly suited for continuous monitoring in high-volume operations.

In addition to technological solutions, regular fuel sampling, laboratory testing, and comparative analysis against EN590 standards remain essential. “Even when using unbranded or ‘white site’ fuel suppliers, it is critical to analyse lubricity and chemical composition to avoid surprises,” highlights FitzGerald.

 

Accountability from Suppliers

ISO-Reliability Partners advises industries to tighten their fuel procurement standards. FitzGerald recommends demanding written certification of compliance with EN590 or similar recognised standards, batch test results for viscosity, density and sulphur, and contractual audit rights. “Fuel suppliers must be held accountable. Choose branded suppliers with traceability and reputation to lose as these are statistically far less likely to be involved in adulteration.”

He also emphasises the value of contractual protections: “Include clauses that enforce penalties for non-compliance, allow immediate termination if adulteration is detected, and mandate traceable sourcing. This creates both a legal and ethical deterrent,” urges FitzGerald.

 

Pursuing Accountability

When adulterated fuel causes equipment failure, industries have strong legal recourse, provided evidence supports the claim. “If damage can be forensically linked to contaminated fuel, and a supplier is found to have breached contract or acted negligently, litigation is absolutely viable,” asserts FitzGerald.

The legal framework is robust. South Africa’s National Environmental Management Act regulates substances like PCBs, while the Consumer Protection Act supports claims of defective or misrepresented fuel. “Service-level agreements are key here,” says FitzGerald. “They provide the foundation for enforcing quality expectations and pursuing legal remedy.”

He also notes that government oversight is catching up. The Department of Mineral Resources and Energy has confirmed over 70 failed fuel samples in a recent inspection, which bolsters industry claims and highlights the regulatory awareness of the issue.

 

A Call to Industry

As South Africa’s industrial sector grapples with economic pressures and environmental challenges, ensuring fuel integrity has become non-negotiable. “The time for passive reliance on fuel suppliers is over. With the right tools, contracts, and vigilance, industries can protect their machinery, personnel, and the environment,” says FitzGerald.

“ISO-Reliability Partners is committed to helping clients implement these safeguards effectively. In an industry where fuel adulteration continues to threaten operational stability, the message is clear: awareness, action, and accountability must go hand in hand,” he concludes.

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Machinery maintenance and the hidden cost of fuel adulteration

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July 1, 2025
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  • Home
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    • Training
    • Press Releases
  • Intro
    • About Us
    • Your Road Map to a Safer Workplace
    • Mining Safety in SA
    • Zero Injuries
    • Prevent Repeat Accidents at Mines
  • Vehicles
    • Tyre Safety
      • Introduction to Tyre Safety
      • The Different Machines And Their Applications
      • Tyre Use
      • Factors affecting tyre wear life
      • Machine Inspection
      • Tyre Inspection
      • Mounting & Demounting Tyres
      • Tyre Inflation
      • Twinning Tyres
      • Ballasting the Tyres
      • Regrooving Tyres
      • Tyre Repairs
      • Tyre Retreading
      • Tyre Handling and Storage
      • Tyre Workshops
      • Glossary
      • Tyre safety, Fires and Explosions in Mines
      • Minimising Tyre Fires and Explosions at our Mines
    • Safe Working/Driving Conditions at Mines
    • Transportation of Dangerous Goods
      • Behaviour Based Safety and Accidents
      • Transportation of Chemicals and AARTO
      • Awareness of Chemicals in Transit
      • Steps to Transport Dangerous Goods Safely
    • Traffic Calming
    • 4×4 Off-Road Driving
      • 4×4 Off-Road Driving Techniques
      • 4×4 Water Crossings
      • 4×4 Driving Hills & Rocky Surfaces
      • 4×4 Driving with Mud Tyres and Mud Driving
      • 4×4 Sand Driving Safety
      • Tools and Spare Parts for Safe 4×4 Driving
      • 4×4 Jacking & Snatch Recovery
      • 4×4 Terrain Knowledge
      • 4×4 Off-Road Driving and Conservation
      • 4×4 Winter Driving
      • 4×4 Driving and Usage of Recovery Straps
      • 4X4 Winch Guide
      • 4×4 Driving and Vehicle Insurance
    • Ctrack Fleet Management
    • Vehicle Maintenance
    • Driver Fitness
    • Rail /Level Crossings and Mining Safety
    • Safe Driving Techniques
    • Fleet Management in the Mining Industry
    • Overloading of Vehicles
  • Tools
    • Essential Tips for Power Tool Safety
    • Prevent and Control Fires when Welding
  • Health
    • Medical Condition
      • Alcohol and Drugs
      • Back Pain
      • Cholera
      • Cholesterol
      • Diabetes
      • Malaria
      • Nutrition
      • STI’S and HIV
      • Tuberculosis
      • Steps to Safer, Healthier Mining Employees
      • Respiratory Silicosis
    • Battery Charging Rooms
    • Vision
      • Eyesight
      • Eye Care and Mining Safety
      • Eye Conditions
      • Clear Vision and Mining Safety
    • Fitness
      • Fatigue
      • Driver Fatigue
    • Hearing
    • Trauma Counseling
  • Gear And Clothing
    • Eye Protection
    • Protective Clothing
    • Preventing Hand Injuries
    • Gloves for Mining Safety
    • Gloves Selection
    • Harness Safety
      • Selection, Fit and Use
      • Equipment Hazards
      • Adjustment of Harnesses
      • Inspection and Maintenance
  • Machinery
    • Lock Out Machinery in the Mining Industry
    • Safety and Mining Machinery
    • Preventing Amputations
      • Introduction
      • Recognizing Amputation
      • Controlling Amputation Hazards Part 1
      • Controlling Amputation Hazards Part 2
      • Specific Machine Hazards Part 1
      • Specific Machine Hazards Part 2
    • Avoiding Accidents
    • Live Testing in the Mining Industry
  • Emergency
    • How to Handle an Emergency!
    • Accident Scene Safety
    • CPR and Mining Safety
    • Post-Traumatic Stress After An Accident
    • Trapped Miner Locators
    • Emergency Preparedness and Response
    • Emergency Medical Response
  • Environment
    • Spill Prevention
    • Environmental Sensing Instruments
  • Training
    • Young Workers Safety at Mines
    • First Rule of Safety: Know Your Job
    • Incident and non-conformance management in the Mining Industry
    • Reducing Mining Accidents by Evaluating Behavior
    • The effect of training on the risk tolerance of workers
    • Hazard Identification at the Mining Site
    • Special Lifting Situations
    • Zero Incidents through SLAM

© 2021 Mining Safety - Mining Safety and Health Education, Information and Advice.