AdBlue® Production Line – AUS32

Models

At Atmosfer Makina, we recognize the escalating global demand for AdBlue® (AUS32), also known as Diesel Exhaust Fluid (DEF). This critical solution is indispensable for modern diesel engines equipped with Selective Catalytic Reduction (SCR) technology, enabling them to meet increasingly stringent emission regulations by converting harmful nitrogen oxides (NOx) into harmless nitrogen and water vapor. As a leader in chemical process engineering, we’ve dedicated ourselves to developing and offering a range of advanced AdBlue® Production Line models designed to empower businesses with the ability to manufacture high-quality AUS32 directly on-site. This approach not only ensures a consistent and reliable supply but also delivers significant economic and operational advantages.

The decision to invest in an on-site AdBlue® production line is a strategic one, particularly for large fleet operators, logistics companies, mining operations, marine businesses, and other industrial consumers with high and consistent demand. Relying solely on external suppliers for AdBlue® can expose operations to unpredictable market fluctuations, potential supply chain disruptions, and the logistical complexities of transporting and storing large volumes of liquid. Our diverse range of AdBlue® Production Line models directly addresses these challenges, offering a robust, self-sufficient, and cost-effective solution.

Our models are carefully engineered to cater to a broad spectrum of production capacities, ensuring that every client, regardless of their scale of operation, can find a system that perfectly aligns with their specific needs. From compact units suitable for moderate daily consumption to large-scale industrial systems designed for continuous, high-volume output, Atmosfer Makina provides a tailored solution. Each AdBlue® production line model is a complete, turnkey solution, minimizing on-site installation time and complexity. We focus on transforming high-purity urea for DEF into ISO 22241 compliant AdBlue®, ensuring the integrity and longevity of your SCR systems.

Our commitment to innovation means that every model incorporates cutting-edge technology, robust construction, and intuitive automation. This ensures reliable performance, consistent product quality, and ease of operation. We believe that empowering our clients with the capability to produce their own AUS32 on-site is a fundamental step towards greater operational control, improved cost efficiency, and a more sustainable future in emission control.

Options

At Atmosfer Makina, we understand that while our standard AdBlue® Production Line models offer exceptional performance, specific operational requirements and environmental conditions can necessitate additional features. That’s why we offer a comprehensive suite of options that allow for extensive customization, ensuring your AUS32 production line is perfectly tailored to your unique needs. These options enhance efficiency, optimize quality, and streamline your entire AdBlue® manufacturing process.

Enhanced urea filtration

The purity of AdBlue® (AUS32) is absolutely paramount for the protection and longevity of Selective Catalytic Reduction (SCR) systems. Even microscopic particulate impurities can lead to blockages or damage within the catalytic converter, resulting in costly repairs and reduced engine efficiency. While our standard AdBlue® Production Line models incorporate robust multi-stage filtration systems designed to meet ISO 22241 standards, some operational environments or specific applications demand an even higher level of purity assurance.

For such demanding scenarios, Atmosfer Makina offers an enhanced urea filtration option. This advanced feature integrates additional, finer filtration stages directly into the AdBlue® manufacturing process. This means that after the urea for DEF has been dissolved in demineralized water, the resulting solution undergoes an even more rigorous purification. This optional filtration mechanism captures the minutest insoluble particles, ensuring that the final AUS32 product is exceptionally pure.

This enhanced urea filtration is particularly beneficial for clients who:

Operate in highly sensitive environments where even minimal impurities could pose a risk.
Procure urea for DEF from sources where consistency in purity might occasionally vary, requiring an additional safeguard.
Wish to maximize the lifespan and performance of their SCR systems by providing the cleanest possible AdBlue®.

By choosing the enhanced urea filtration option, you invest in an added layer of quality assurance, further protecting your valuable diesel engine assets and guaranteeing the highest possible standard for your on-site AdBlue® production.

Low energy heating

Maintaining optimal temperature during the urea dissolution process is crucial for efficient and consistent AdBlue® manufacturing. In colder climates or during winter months, the temperature of incoming demineralized water can drop, slowing down the dissolution rate of urea for DEF and potentially impacting production capacity. Traditional heating methods can be energy-intensive, adding to operational costs.

Atmosfer Makina addresses this challenge with our low energy heating option for the AdBlue® Production Line. This feature incorporates highly efficient heating elements and advanced temperature control systems that are specifically designed to minimize energy consumption while effectively warming the demineralized water to the ideal temperature range for urea dissolution (typically between 25-40°C).

The benefits of implementing a low energy heating system include:

Consistent Production Rates: Ensures that the dissolution process remains efficient regardless of ambient temperature, maintaining stable AUS32 output.
Optimized Dissolution: Warmer water accelerates the dissolution of urea for DEF, reducing batch times and increasing overall efficiency of the AdBlue® manufacturing process.
Reduced Energy Costs: Utilizes advanced, energy-efficient technology to minimize power consumption, contributing to lower operational expenditures over the long term.
Prevents Crystallization: Helps prevent the formation of urea crystals, which can occur if dissolution is inefficient in cold conditions, safeguarding system components.

This low energy heating option is a smart investment for any AdBlue® Production Line operating in variable climates, ensuring uninterrupted and cost-effective AUS32 manufacturing throughout the year.

Storage

Once the AdBlue® (AUS32) has been produced to the highest quality standards by our AdBlue® Production Line, efficient and safe storage becomes a critical next step before distribution or direct use. Atmosfer Makina offers a range of comprehensive storage solutions designed to seamlessly integrate with your AdBlue® manufacturing process, ensuring the integrity and ready availability of your finished product.

Proper storage is vital to maintain the quality and extend the shelf life of AdBlue®. AdBlue® is sensitive to contamination and extreme temperatures. Our storage solutions are engineered with these factors in mind:

Material Compatibility: Our storage tanks are constructed from materials that are fully compatible with AdBlue®, such as high-grade stainless steel or specific types of high-density polyethylene (HDPE). These materials prevent any chemical reactions that could contaminate or degrade the AUS32, ensuring it remains ISO 22241 compliant.
Capacity Options: We offer a wide variety of storage capacities to match your AdBlue® production line’s output and your consumption needs. Whether you require small buffer tanks or large bulk storage solutions capable of holding thousands of liters of DEF, we have an option for you.
Temperature Control Features: For regions with extreme climates, our storage tanks can be equipped with insulation and, if necessary, heating or cooling systems. This helps maintain AdBlue® within its ideal storage temperature range (typically -11°C to 30°C), protecting it from freezing in very cold conditions or from thermal degradation in very hot environments. This ensures product stability and performance over time.
Integrated Level Monitoring: Our storage tanks come with integrated level sensors that provide real-time inventory data. This allows for precise monitoring of stock levels, enabling efficient planning for production batches and preventing costly shortages. Automated alerts can be configured to notify operators when AdBlue® levels are low or critical.
Ventilation and Sealing: Proper tank design includes features for adequate ventilation to prevent vacuum or pressure buildup during filling and dispensing. Simultaneously, the tanks are sealed to protect the AUS32 from airborne contaminants, dust, and light exposure, all of which can degrade AdBlue® quality.

By offering these robust storage solutions, Atmosfer Makina ensures that the high-quality AdBlue® produced by your AdBlue® Production Line remains pristine until it’s needed, providing a complete and reliable on-site AdBlue® supply chain.

Packaging solution

After your AdBlue® Production Line has efficiently manufactured high-quality AUS32, the final stage often involves transferring the finished product for distribution or immediate use. Atmosfer Makina provides comprehensive packaging solution options designed to streamline this process, ensuring efficient, accurate, and safe handling of your self-produced AdBlue® (DEF). Our solutions cater to a variety of dispensing and distribution needs, from bulk transfers to individual container filling.

Our packaging solution options are integrated with the output of your AdBlue® manufacturing process or directly with your storage tanks, creating a seamless workflow:

Bulk Loading Systems: For clients requiring large volumes of AdBlue® for their own fleets or for sale to other bulk consumers, we offer automated bulk loading stations. These systems are equipped with high-capacity pumps, precision flow meters, and articulated loading arms that allow for rapid and safe transfer of AUS32 into tanker trucks. Automated shut-off valves prevent overfilling, ensuring efficient and mess-free operations. These systems are ideal for large logistics centers, fuel depots, or major industrial sites.
IBC Tank Filling Stations: Intermediate Bulk Containers (IBC Tanks) are a popular choice for storing and transporting AdBlue® in manageable quantities (typically 1000 liters). We provide specialized filling stations designed specifically for IBC Tanks. These stations ensure accurate filling volumes, minimize spillage, and can be automated for high throughput. This packaging solution is perfect for clients who distribute AdBlue® to multiple internal departments, smaller client sites, or for resale in medium volumes. Our solutions can include features for automatic cap placement and sealing for enhanced efficiency.
Drum and Small Container Filling Lines: For operations that require distributing AdBlue® in smaller volumes, such as 200-liter drums or even smaller containers (e.g., 10-liter jugs), Atmosfer Makina offers semi-automated or fully automated filling lines. These systems are designed for precision filling, minimizing product waste and ensuring consistent packaging. They are ideal for retail distribution, service stations, or internal use where smaller, portable quantities are preferred.
Integrated Weighing and Labeling: To ensure accuracy and compliance, our packaging solution options can include integrated weighing systems for precise volume verification and automated labeling machines. This streamlines the entire post-production process, making the AdBlue® manufacturing process complete from raw urea for DEF to ready-to-distribute product.

Every packaging solution we offer is designed with a strong emphasis on safety, incorporating features such as spill containment, emergency stop buttons, and operator-friendly interfaces. By providing these comprehensive packaging solution options, Atmosfer Makina empowers you to not only produce high-quality AdBlue® efficiently but also to manage its storage and distribution effectively, securing your entire AdBlue® supply chain and maximizing the value of your AdBlue® Production Line.

Frequently Asked Questions (FAQ)

Q: What is the primary benefit of investing in an Atmosfer Makina AdBlue® Production Line?

A: The main benefit is gaining complete control over your AdBlue® (AUS32) supply. This ensures an uninterrupted, high-quality supply, significantly reduces logistical costs associated with purchasing pre-made AdBlue®, and provides independence from external market fluctuations, leading to long-term economic and operational advantages.

Q: What raw material is used in your AdBlue® Production Line?

A: Our AdBlue® Production Line uses high-purity urea for DEF (Diesel Exhaust Fluid) as its primary raw material. This granular urea is precisely mixed with demineralized water in our automated process to produce AUS32 that meets the ISO 22241 standard.

Q: How does your production line ensure the quality of the AdBlue® (DEF) it produces?

A: Our AdBlue® production line ensures top quality through automated, precise dosing, multi-stage filtration, and continuous real-time monitoring of critical parameters like concentration and conductivity. We also offer an enhanced urea filtration option for even greater purity assurance, guaranteeing ISO 22241 compliance.

Q: Can your AdBlue® Production Line operate efficiently in cold climates?

A: Yes. Our systems can be equipped with a low energy heating option for the water used in the AdBlue® manufacturing process. This ensures optimal urea dissolution regardless of ambient temperature, maintaining consistent production rates and preventing crystallization in colder environments while minimizing energy consumption.

Q: What kind of storage solutions do you offer for the finished AdBlue®?

A: We offer various storage tank options for finished AdBlue® (AUS32), designed for material compatibility and capacity to match your needs. These tanks can include features like insulation for temperature control and integrated level monitoring, ensuring the quality and ready availability of your produced DEF.

Q: Can I package the AdBlue® produced by your line into IBC Tanks or drums for distribution?

A: Absolutely. We provide comprehensive packaging solution options, including dedicated filling stations for IBC Tanks and automated or semi-automated lines for drums and smaller containers. These solutions are designed for efficient, accurate, and safe transfer of your AUS32 for distribution or internal use.

Q: What capacities do your AdBlue® Production Line models offer?

A: Our AdBlue® Production Line models are designed for various capacities, ranging from those suitable for moderate daily consumption to high-capacity automated AdBlue® production systems capable of producing up to 150m³/day or more, depending on your specific requirements. We tailor the solution to your needs.

Q: Is the AdBlue® Production Line easy to operate?

A: Yes, our AdBlue® Production Line is designed to be an easy-to-use system. It features intuitive Human-Machine Interfaces (HMIs) and advanced automation that manages the complex AdBlue® manufacturing process, reducing the need for extensive training and ensuring smooth, efficient operation with minimal manual intervention.

Q: What kind of support does Atmosfer Makina provide after the purchase and installation?

A: Atmosfer Makina offers comprehensive after-sales support. This includes expert technical assistance, maintenance guidance, and prompt troubleshooting to ensure your AdBlue® Production Line operates efficiently and reliably for its entire lifespan. We are committed to your ongoing success.

Contact Atmosfer Makina

Ready to transform your chemical production with intelligent automation?

The path to faster, more precise, and more profitable chemical manufacturing begins with the right filling and packaging machinery. Contact us today to discuss a tailored solution for your specific needs.

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Location	Kızılcaşar MAh. 4200 cad. no:39 Atabilge incek Sitesi c blok d:140 Gölbaşı /Ankara
Office Phone	+90 312 504 64 60
Mobile / WhatsApp	+90 541 947 04 14
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