Producing high-quality fuel requires absolute precision, especially when it comes to water purity. As a diesel exhaust fluid used to reduce harmful emissions, fuel manufacturing companies must comply with ISO 22241 standards, meaning the water used in its formulation must be exceptionally clean, free from contaminants, and chemically stable.
At a Manufacturing and Logistics Company in Johannesburg, a high-volume fuel manufacturing plant, maintaining this level of water quality is essential to ensure regulatory compliance, protect equipment integrity, and guarantee product performance. To strengthen water reliability and improve production consistency, we delivered a complete turnkey water-management solution designed specifically for the demands of AdBlue manufacturing.
Standard-Compliant Treatment for High-Purity Water Production
Ultra-pure water is critical to ensuring consistent, high-quality fuel manufacturing. To meet the stringent requirements of both national and international regulations, the entire treatment system was engineered in accordance with SANS 10299 water-treatment design protocols and SANS 241 potable-water quality standards. By adhering to these specifications, the plant receives a stable supply of clean, contaminant-free water that supports ISO 22241 compliance and safeguards against issues such as crystal formation, corrosion, and reduced DEF performance.
High-Capacity Water Storage for Continuous Production
To ensure uninterrupted manufacturing and maintain consistent water purity, we installed a high-capacity water-storage facility designed specifically for ultra-pure water. These tanks help stabilise supply during peak production periods and protect water quality by preventing exposure to contaminants or environmental fluctuations. This secure buffer ensures that Nungufreight can maintain steady output without interruptions caused by short-term demand spikes or maintenance cycles.
Geological Mapping & Ground Study for Sustainable Supply
Before installing the water infrastructure, our geological team conducted a detailed ground study to assess underground water availability and long-term sustainability. This assessment helped identify productive aquifer zones, guide extraction planning, and ensure the plant would have reliable access to sufficient raw water for years to come.
Ultra-Pure Water Treatment Plant for Fuel Manufacturing
Fuel production requires extremely pure water with tight chemical controls. To achieve this, we designed and installed a complete treatment train capable of meeting and maintaining ultra-low contaminant levels.
The system integrates:
- Reverse Osmosis (RO) to remove dissolved minerals, salts, and impurities
- Deionisation (DI) units to achieve ultra-low conductivity water (<5 µS/cm)
- UV sterilisation to eliminate microbial contaminants
- Carbon and sediment filtration to remove chlorine, particulates, and organic matter
- Water softener
- Ozone disinfection
This multi-stage approach ensures the water used in blending and formulation consistently meets the strict quality parameters required for fuel production.
Water Heating Plant for Temperature-Controlled Production
Certain stages of the manufacturing process require stable water temperatures to optimise dissolution, blending, and consistency. To support this, we installed a dedicated water-heating plant that delivers precise thermal control while reducing overall energy consumption. This ensures smooth production flow, improved mixing efficiency, and reduced chemical variability.
Ensuring Optimum Water Quality for AdBlue
To comply with ISO 22241, the treated water must meet extremely strict quality specifications, including:
- TDS: < 0.5 mg/L
- Electrical conductivity: < 5 µS/cm
- Chloride & sulphate: < 0.5 mg/L each
- Heavy metals: < 0.2 mg/L
- Organic matter & bacteria: non-detectable
Our treatment system was engineered to consistently achieve these parameters, protecting both the production process and the final product.
Project Outcome
The company in Johannesburg benefits from a stable, ultra-pure water supply that meets the stringent requirements of fuel production. The advanced RO and deionisation systems ensure reliable purity for every batch, safeguarding ISO 22241 compliance and strengthening product integrity.
The geological study supports sustainable long-term water sourcing, while the high-capacity storage system ensures uninterrupted production even during peak demand. The water-heating plant enhances efficiency and process stability, reducing energy consumption and improving blending consistency.
Together, these integrated water-management upgrades have significantly improved operational reliability, regulatory compliance, and production efficiency, enabling them to maintain consistently high standards across their manufacturing operations.
Ready to Improve Your Industrial Water Quality?
If your manufacturing facility relies on high-purity water or you’re looking to upgrade your processing standards, iWater Management can design a turnkey water strategy tailored to your operational demands. From advanced RO and DI systems to SANS-compliant treatment, heating solutions, and sustainable resource planning, our team is ready to support your production goals.
Contact us to create a customised water-management solution that enhances performance, protects product quality, and ensures long-term reliability.
