Close-up of the hand of a technician working with three-dimensional verification and measuring machine in a cnc innovative metal factory
Back to Blog
Planning

How to Calculate Your Fleet's AdBlue® Consumption

September 2024
6 min read

Accurate AdBlue® consumption forecasting helps you optimize ordering, avoid running out, and budget effectively. This guide provides simple calculation methods and industry benchmarks to predict your fleet's needs.

The Basic Consumption Rule

General Formula

3-6%

AdBlue® consumption is typically 3-6% of diesel consumption

For every 100 liters of diesel, expect to use 3-6 liters of AdBlue®

Factors Affecting Consumption

Emissions Standard

  • • Euro 4/5: ~3-4% consumption
  • • Euro 6: ~4-6% consumption
  • • Newer standards = higher usage

Driving Conditions

  • • Highway: Lower consumption
  • • City/Stop-start: Higher usage
  • • Heavy loads: Increased rates

Vehicle Type

  • • Light commercial: 3-4%
  • • Heavy trucks: 4-5%
  • • Buses: 5-6%

Temperature

  • • Cold weather: Slightly higher
  • • Hot weather: Standard rates
  • • Engine temp affects SCR efficiency

Step-by-Step Calculation Methods

1 Method 1: Based on Diesel Consumption

Step 1: Record total diesel used last month (e.g., 10,000L)

Step 2: Multiply by 0.04 (4% average): 10,000 × 0.04 = 400L

Step 3: Add 15-20% buffer for safety: 400 × 1.2 = 480L

Result: Order ~500L AdBlue® per month

2 Method 2: Based on Fleet Size & Usage

Step 1: Count active vehicles (e.g., 20 trucks)

Step 2: Estimate km per vehicle per month (e.g., 5,000 km)

Step 3: Estimate fuel economy (e.g., 30L/100km)

Step 4: Calculate: (5,000 ÷ 100) × 30 = 1,500L diesel per truck

Step 5: Total fleet: 1,500 × 20 = 30,000L diesel

Step 6: AdBlue®: 30,000 × 0.04 = 1,200L per month

Result: Order ~1,500L AdBlue® per month (with buffer)

3 Method 3: Track Actual Usage

Best for: Operations with digital meters or tracking systems

Step 1: Record AdBlue® tank level at month start

Step 2: Record tank level at month end

Step 3: Add any deliveries received during month

Step 4: Calculate: (Start level + Deliveries) - End level = Actual usage

Result: Most accurate method—use 3 months of data to establish pattern

Example Calculations by Fleet Size

Small Fleet (10 Vehicles)

• Diesel: ~15,000L/month

• AdBlue® needed: 600L/month (at 4%)

• Recommended: 10L bottles (60 bottles) or 1× IBC (1000L) every 6 weeks

Medium Fleet (30 Vehicles)

• Diesel: ~45,000L/month

• AdBlue® needed: 1,800L/month (at 4%)

• Recommended: 5,000L slimline tank with monthly bulk delivery

Large Fleet (75 Vehicles)

• Diesel: ~110,000L/month

• AdBlue® needed: 4,400L/month (at 4%)

• Recommended: 10,000L round tank with bi-monthly bulk delivery

Optimizing Your Ordering Schedule

Weekly Monitoring

Check AdBlue® levels weekly. Set reorder points at 25-30% capacity to avoid emergency orders.

Track Seasonal Variations

Some operations use more fuel in certain seasons. Adjust ordering based on historical patterns.

Schedule Regular Deliveries

Set up automatic delivery schedules with your supplier. Removes guesswork and prevents running out.

Build in Buffer Stock

Always maintain 15-20% extra capacity for unexpected increases in fleet activity or delivery delays.

Budget Accurately

Knowing consumption patterns helps forecast costs. Factor AdBlue® into per-vehicle or per-km operating costs.

Key Takeaways

  • Standard consumption: 3-6% of diesel usage (4% is a good average)
  • Track actual usage for 2-3 months to establish your fleet's pattern
  • Always add 15-20% buffer to calculations
  • Newer Euro 6 vehicles use more AdBlue® than older Euro 4/5
  • Set up regular delivery schedules to avoid running out
Reliable Supply Partner

Let Us Help You Plan Your AdBlue® Supply

EZ Fluid Solutions can help you calculate your needs and set up a reliable delivery schedule. Never run out again.

View Supply Options Request a Quote
Back to Blog