Fuel Troubles in the Cold? Here’s What to Do

Snow in the South is rare, but when it happens, it can feel like the world has flipped upside down. From Texas to North Carolina, heavy snow, freezing fog, and frigid winds have transformed landscapes and brought everyday activities to a grinding halt. For those who depend on diesel fuel, this unusual cold snap adds an extra layer of challenges. Diesel fuel, which performs reliably in warm climates, becomes at risk of gelling in these freezing conditions—leaving engines struggling to start and equipment out of commission. Understanding how to prevent and address gelling is now essential for staying ahead in this uncommon Southern freeze.

What Causes Diesel Gelling?

When temperatures drop below a diesel fuel’s cloud point, wax crystals begin to form in the fuel. As temperatures fall further, these crystals grow and thicken, eventually clogging fuel lines and filters. This process is known as diesel gelling, and it can prevent your engine from starting or running efficiently.

• Cloud Point – The temperature at which wax begins to crystallize out of the fuel. Cloud points are usually less than 10° F for diesel fuel.
• Cold Filter Plug Point (CFPP) – The lowest temperature at which fuel can flow through a filter.
• Gelling Temperature – Once below the CFPP, diesel fuel thickens to the point that it can no longer flow properly.

In addition to gelling, water in your fuel tank can freeze below 32°F (0°C), creating issues that mimic gelling. A quick inspection of your filter can help differentiate between the two. If the buildup is waxy, gelling is likely the problem. Ice formation, however, points to water contamination.

Signs of Diesel Gelling

To avoid delays or damage to your equipment, watch for these signs:

• Reduced or No Fuel Flow – Gelled fuel can clog pumps and lines.
• Engine Struggles – Engines may sputter, fail to start, or run sluggishly.
• Waxy Buildup – A waxy residue on your tank’s filter is a clear indicator of gelling.

 

How to Treat Gelled Diesel Fuel

If your diesel has gelled, don’t panic—there are effective ways to restore functionality. Here’s a step-by-step approach:

1. 1.Use Emergency Additives

Use a specialized re-liquefier like Innospec Red Alert or Arsenal FIRST-AID. These additives are designed to dissolve wax crystals and restore the fuel to a usable state. You can add the product directly to the fuel tank and the engine’s filter. Then, allow time for the additive to circulate and break down the wax deposits.

2. Blend with Kerosene

Adding a short load of kerosene can lower the cloud point and help restore fuel flow. For example, blending 1,200–3,200 gallons of kerosene into a 4,800-gallon tank creates a 20–40% mix, making the fuel usable in colder temperatures.

3. Replace Clogged Filters

If your fuel filter is completely blocked, replacing it can help restore operability. Ensure the new filter is compatible with your cold-weather blend.

4. Drain Water from the Tank

If ice formation is an issue, remove water from the tank using a water separator or drain valve. Winter additives designed to disperse water can also help prevent future freezing.

 

Preventing Diesel Gelling Before It Happens

Preparation is the key to avoiding diesel gelling, especially during unexpected cold snaps.  Here are practical steps to ensure your fuel stays flowable:

Use Cold-Weather Additives

Treat your diesel fuel with cold-weather additives like ColdPRO before temperatures drop. These products lower the cloud point and prevent wax crystals from forming. In extreme cold, double the recommended dose for added protection.

Pre-Blending with Kerosene

When temperatures drop to extremes—such as -20°F—kerosene becomes essential. Work with your fuel supplier to pre-blend kerosene into your diesel during winter months. This lowers the fuel’s cloud point and ensures it remains flowable even in subfreezing temperatures. You can learn more about the differences between kerosene and winter additives here.

Maintain Your Tanks

Inspect your fuel tanks regularly for water contamination. Drain any water using separators or tank drain valves. Water in the tank can freeze and exacerbate gelling issues. Ensure tank vents are clear to prevent ice blockages. Check out here if your tanks are ready for winter.

Order Winterized Diesel

Many suppliers offer winterized diesel blends that are formulated to handle colder temperatures. These fuels are pre-treated with additives to prevent gelling.

 

Key Takeaways for Managing Diesel in Cold Weather

1. Treat Fuel Early – If temperatures are expected to drop below normal in the coming days, consider using winter additives in advance to prevent fuel gelling.
2. Stock Emergency Supplies – Keep re-liquefying additives and kerosene on hand for emergencies.
3. Inspect and Maintain Tanks – Remove water and ensure tanks are clean and winter-ready.
4. Work with a Trusted Supplier – Collaborate with a fuel supplier to ensure you have access to winterized diesel or kerosene blends.

Stay prepared, and don’t let the cold weather catch you off guard.

Talk to The Specialist

Mansfield’s Arsenal ColdPRO is a program to improve your fuel’s cold-weather performance, offering consistent and accurate treatments, minimizing kerosene cost, and performing nationwide fuel testing.

Implementing Mansfield’s Arsenal ColdPRO program ensures your fuel systems operate efficiently throughout the winter season. If you haven’t already, contact Mansfield to learn more about Arsenal Cold Pro. Don’t wait; contact us today to secure a worry-free winter for your fuel needs.