Are fuel spillages more likely in winter?

As a fleet operator, you’ll have seen firsthand the challenges brought by winter weather. From icy roads and frozen equipment to shorter daylight hours, this particular season can make refuelling more challenging, slowing operations and increasing the chance of delays and mishaps. Amongst these issues, there’s one risk that should never be overlooked, and that’s fuel spillage. A major problem at any time of the year, it can reach new heights in winter, leaving fleets especially vulnerable.

Fortunately, there are steps you can take to keep your fuel safe through the colder months and beyond. At TankSafe, we’ve helped countless fleets protect their trucks and preserve their profits with our pioneering TankSafe® Optimum 9 device, and we know the impact fuel loss can have on a business. Understanding why fuel spillages increase in winter and finding the right ways to prevent them makes all the difference, and that’s exactly where we can help. Let’s dive in!

Cold weather changes fuel behaviour

During the colder months, managing diesel can be particularly tricky. As temperatures drop, the naturally occurring paraffin waxes in the fuel can crystallise, causing it to ‘gel’ and become thick and sludgy. This can make refuelling less predictable and more challenging, particularly for commercial vehicles with large-capacity tanks. Slow or uneven fuel flow increases the chance of splashbacks, accidental overfills, or minor spillages, and though drivers may instinctively try to compensate by pumping faster or tilting the nozzle, this can actually make the problem worse.

Equipment is affected by the temperatures

It’s not just the fuel that changes in winter; the equipment designed to contain it is affected, too. Fuel caps, seals and filler necks can contract slightly in colder temperatures, making rubber and plastic components stiffer and less flexible. This reduced elasticity can compromise the seal during refuelling, increasing the likelihood of small amounts of diesel escaping. Combined with the slower flow of thickened fuel, even routine topping-up requires extra care.

Condensation and hidden fuel loss risks

Cold weather brings another challenge for fleets that’s easy to overlook: condensation inside fuel tanks. Moisture from the air can collect on the inside of tanks as temperatures drop, introducing small amounts of water into the diesel. While this might seem like a minor issue, it can actually have a significant impact over time. Water in tanks can accelerate corrosion on metal surfaces, particularly around seams, joints and filler necks. This corrosion weakens the tank structure and can eventually lead to small leaks. Condensation can also compromise rubber seals and gaskets, causing them to swell, crack, or lose flexibility, and leading to similar fuel loss.

Challenging refuelling conditions place pressure on drivers

Winter also introduces environmental factors that make refuelling riskier. Icy or wet forecourts, frost and shorter daylight hours all make handling pumps and nozzles more difficult. When combined with rushed schedules and heavier seasonal workloads, drivers may need to work faster to keep to schedules in poor conditions, or deal with reduced visibility that affects their ability to gauge fuel levels accurately. In these circumstances, what might be a routine task in summer can quickly become risky, creating serious safety hazards for staff and other vehicles.

Taking action to prevent fuel loss in winter

As you’ll know all too well, fuel spillages and leaks can be incredibly costly and hazardous, increasing operating costs, creating safety and environmental risks and leading to fines or even reputational damage. While winter clearly increases the likelihood of fuel spillages, fleets don’t have to accept these losses as inevitable. Taking a proactive approach to fuel management not only protects your diesel but also keeps drivers safe and depot operations running smoothly. By understanding the seasonal risks and implementing practical measures, you can significantly reduce the likelihood of fuel spillages, enjoying peace of mind even in the harshest conditions.

Monitor and maintain equipment

Regular inspection of fuel caps, seals, filler necks and tanks is essential, particularly during the winter months when components are under extra stress. Even small issues like minor cracks or slightly misaligned caps can increase the likelihood of fuel spilling during refuelling, which is why regular inspections and maintenance go such a long way. Fleet operators need to check equipment routinely and address any signs of wear or damage immediately to prevent small issues from turning into costly winter fuel losses, while also keeping refuelling safer for drivers and depot staff.

Adjust refuelling practices

In winter, drivers can reduce the risk of fuel issues by following simple, proven refuelling practices. Refuelling steadily and avoiding rapid or repeated ‘top-ups’ helps prevent splashback and overfilling, which are common causes of spillages in colder conditions. Where possible, keeping tanks reasonably full reduces the amount of air inside the tank, limiting condensation caused by overnight temperature changes. Refuelling at the end of a shift can support this by ensuring the tank is fuller during the coldest part of the day. Taking a moment to check that the nozzle is properly seated and the fuel cap is securely replaced before moving on also helps to prevent avoidable spills, particularly when cold weather, gloves, or low light make handling more difficult.

Track fuel levels

If left undetected, small losses can accumulate over time, costing fleets significant amounts of money. Keeping a close eye on fuel levels is an essential preventative measure, especially in winter when minor spillages are more likely to occur. By monitoring consumption and conducting regular checks on tank readings, operators can quickly spot discrepancies that may indicate a spillage or inefficient refuelling. Proactive tracking also enables managers to identify patterns, address issues before they escalate, and maintain tighter control over fuel budgets throughout the colder months.

Invest in TankSafe® technology

The most reliable way to prevent fuel loss, regardless of the season, is with proven, reliable technology like anti-siphon devices. Our groundbreaking TankSafe® Optimum 9 solution prevents overfilling, skimming, siphoning and spillages by isolating the fuel as the tank fills. Its patented float valve rises with the fuel and locks off at 98% capacity, providing a simple but highly effective barrier against all kinds of fuel loss before they occur.

Are you ready to protect your fuel through winter and beyond? With TankSafe® Optimum 9, you can maintain efficient, cost-effective fleet operations all year round, typically achieving a return on investment within just three to six weeks. Installation is quick and simple, taking less than five minutes per vehicle, yet the benefits last for the lifetime of the tank. For more information, don’t hesitate to give us a call on 01253 400 401 today, and we’ll get you started on the road to peace of mind and fuel security.