Turning Biodiesel Storage Issues into a Problem of the Past

Benecor systems are designed to simplify installation while maximizing performance. (Photo: Benecor Inc.)

Benecor’s end-to-end approach to fuel storage and dispensing reduces risk, shortens timelines and delivers a higher level of confidence for customers adopting biodiesel.

Benecor is an industry leader in diesel exhaust fluid (DEF), diesel and renewable fuel storage and dispensing equipment. From our manufacturing facility in Fenton, Michigan, we design, engineer and deliver complete fueling solutions tailored to the unique needs of each customer.

Founded in 2005, Benecor has built its reputation on innovation, particularly in DEF and fueling systems across commercial, industrial and retail markets. With sales, engineering, technical service and manufacturing all handled in-house, we maintain full control over quality and performance. Fuel storage and dispensing systems are not just part of what we do—they are our singular focus. That specialization combined with a hands-on, entrepreneurial approach continues to position Benecor as a trusted partner and industry resource, frequently sought out by leading committees and associations.

Solving Biodiesel Storage, Dispensing Challenges

As commercial fleets transition to higher biodiesel blends—and in some cases B100—fuel storage and dispensing infrastructure must evolve accordingly.

We were approached by the largest biodiesel producer in the world to develop a practical, field-ready solution capable of addressing these challenges. Leveraging two decades of experience designing heated and insulated DEF systems, we applied proven engineering principles to biodiesel—validating requirements, identifying risks and developing systems purpose-built for real-world conditions.

Why Biodiesel Storage Requires a Different Approach

Biodiesel introduces several critical variables that differ from petroleum diesel:

• Temperature sensitivity: Higher cloud points require consistent heat management to prevent gelling.

• Material compatibility: Contact with certain metals (copper, brass, lead, tin, zinc) can accelerate fuel degradation.

• Seal integrity: Incompatible elastomers can swell, leading to leaks and system failures.

• Water and microbial growth: Biodiesel’s hygroscopic nature increases the risk of contamination and fuel breakdown.

These factors demand a system-level solution—not just component-level adjustments.

Engineering the Solution

Benecor’s approach focused on designing a complete, integrated system rather than modifying existing diesel infrastructure.

We engineered heating and insulation strategies for aboveground steel tanks across multiple configurations, ensuring fuel remains within optimal temperature ranges. Material selection was equally critical—utilizing black steel, stainless steel and aluminum, along with Viton seals and O-rings to maintain fuel integrity and system longevity.

Dispensing systems were also redesigned. Standard diesel dispensers often struggle in colder environments, so we incorporated heated components throughout the dispensing chain—from tank to nozzle—ensuring consistent flow and performance.

The result is a fully engineered system that performs reliably in demanding environments while protecting fuel quality from storage through dispensing.

Engineered Systems Built for the Field

Benecor systems are designed to simplify installation while maximizing performance. In many applications, our solutions can be deployed as plug-and-play systems, significantly reducing field labor and installation time.

Factory-integrated features include:  

• Insulated tank systems.

• Thermostat-controlled heating (tank, piping and dispenser).

• Prewired power and control panels.

• Integrated tank monitoring and compliance systems.

• Submersible pumping systems.

• Onboard or remote dispensing configurations.

These systems are engineered holistically ensuring every component works together seamlessly. The result is improved reliability, reduced installation timelines and lower total project costs.

Additionally, Benecor offers flexible system configurations, including double-wall polyethylene tank options for certain applications. These systems can provide a cost-effective alternative to steel while maintaining performance in controlled environments.

Aboveground Vs. Underground Storage Considerations

Selecting between aboveground storage tanks (ASTs) and underground storage tanks (USTs) plays a significant role in biodiesel performance and lifecycle cost.

USTs offer protection from temperature fluctuations and ultraviolet (UV) exposure, which can help stabilize fuel. They are more susceptible, however, to water intrusion and microbial growth—two critical concerns for biodiesel.

ASTs, on the other hand, provide greater accessibility for inspection, cleaning and maintenance. When paired with proper heating and insulation, AST systems offer a practical and cost-effective solution, particularly for fleet applications where uptime and serviceability are priorities.

From a cost and deployment perspective, AST systems typically offer faster installation, lower upfront costs and the added benefit of relocatability—making them an attractive option for many operations.

The Benecor Process: From Concept to Commissioning

What sets Benecor apart is not just the equipment but the process behind it. Every project follows a structured, collaborative approach designed to deliver precision-engineered solutions tailored to real-world conditions. This end-to-end approach reduces risk, shortens timelines and delivers a higher level of confidence for customers adopting biodiesel.

Consultation

We begin by understanding the full scope of your operation—fuel type, climate conditions, regulatory requirements, site constraints and long-term goals. This ensures the solution is built around your application, not adapted after the fact.

Engineering, Design

Our in-house engineering team develops a fully customized system, optimizing performance, efficiency and compliance. Every detail—from material compatibility to thermal management—is carefully considered.

3D Concepting, Visualization

Before manufacturing begins, customers receive detailed 3D renderings of their system. This step ensures alignment, eliminates surprises and allows for refinement prior to production.

Systems Integration, Manufacturing

Unlike pieced-together field systems, Benecor solutions are fully integrated at the factory. Pumps, controls, heating elements and monitoring systems are engineered and assembled as one cohesive unit—ensuring quality, compatibility and performance.

Logistics, Delivery

Our team coordinates the safe and efficient delivery of fully assembled systems, minimizing on-site complexity and ensuring readiness upon arrival.

Installation, Commissioning

We support installation through start-up and commissioning, ensuring systems are fully operational and optimized from Day One.

Benecor’s B99 system opened at Pilot’s Urbandale, Iowa, location in May 2025. (Photo: Benecor Inc.)

Proven in Real-World Applications

Benecor’s engineered biodiesel systems are actively supporting operations across North America.

We have deployed solutions at private-fleet facilities, government operations and retail-fueling environments, each with unique requirements and performance expectations.

Notable installations include:

• Fleet-fueling systems supporting major brands such as PepsiCo, where reliability and uptime are critical to daily logistics operations.

• Multiple municipal and federal government entities across the U.S., where compliance, safety and durability are paramount.

• Retail-fueling deployments at Pilot locations, including sites in Dallas and Iowa, supporting the expansion of biodiesel availability in high-traffic commercial corridors.

These installations demonstrate the versatility of Benecor systems—performing across climates, applications and fuel types.

Looking Ahead

As biodiesel adoption continues to grow, the importance of proper storage and dispensing infrastructure cannot be overstated. Poor system design can lead to fuel degradation, operational inefficiencies and increased maintenance costs.

Benecor’s engineered approach transforms these challenges into opportunities—delivering reliable, efficient and future-ready fueling systems that support the continued growth of renewable fuels.

With the right infrastructure in place, biodiesel storage challenges can truly become a problem of the past. Whether you’re upgrading existing infrastructure or building a new fueling solution, Benecor is ready to deliver a system designed to perform.

Author: Brad Crawford

Director of Engineered Fuel Systems

Benecor

248-437-4437

brad.crawford@benecor.com