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5 Common Problems in Diesel Fuel and How a Diesel Filtration System Solves Them
From trucks and ships to industrial machines and power generators, diesel engines are built to last. While they are trusted worldwide for their durability and efficiency, here's one hidden factor that can even bring the most powerful diesel engine to its knees, and that is the fuel quality of the system. If your diesel is dirty, contaminated, or not maintained properly, you'll face endless breakdowns, costly repairs, and frustrating downtime. That's where the fuel filtration comes in.
So, in today's blog, we will walk you through the five most common problems you may face in diesel fuel, their causes, and how you can fix them perfectly. Keep reading until the end to find out what the experts of Njord Filtration have to say.
Why is Diesel Filtration Important?
Before we get into the problems, it's essential to understand why diesel fuel filtration is necessary. Now, as you already know, diesel degrades over time, and unlike gasoline, diesel fuels are easier to get contaminated. Amongst which, water caused by condensation or leaks is one of the biggest enemies of a healthy fuel. Because this stored water also invites microbial organisms, which are often accompanied by dirt and debris, thereby lowering the overall quality and potential of the diesel fuel.
But you won't replace the diesel regularly. Instead, you need to invest in the best and most effective ways, that is, filtering the fuel with the help of a polishing system. When you buy the diesel fuel polishing system by Njord Filtration, it will not only remove water, sludge, and dirt from the fuel but also protect the pump, engine, and injectors so that the fuel is stored efficiently without letting the dirt and condensation become an issue.
(Also read from our previous blogs: Fuel Maintenance Systems: Protecting Your Investment and Reducing Downtime )
5 Common Problems in Diesel Fuel and How to Solve Them?
The following are the top five most common problems in Diesel Fuel, with practical solutions:
- Microbial Growth, aka the Diesel Bug
The Problem: As we mentioned earlier, when water meets diesel, the microbial growth starts to produce. This will eventually create a slimy sludge called the diesel bug that clogs filters, corrodes tanks, and produces acid and foul smell that affects the quality of the fuel and the system.
Signs: if you notice blocked filters after a short time, slimy black or green deposits in the tank, and the engine performance is degrading, this means there's microbial growth in the fuel.
Solution: Diesel filtration system will remove water by cutting off the microbes' breeding ground, filter out sludge and biomass while maintaining a healthy fuel environment side by side.
- Water Contamination
Problem: Well, water is the main culprit, obviously. It becomes the breeding ground for every microbe that can infect the fuel quality. Most of the time, condensation is the reason for water, but sometimes water leaks or occurs during fuel deliveries, too. The game begins when this water enters the system, causing rust in the tanks and pipes. Apart from that, it also encourages the diesel bug to grow and damage the injector and cause engine misfire.
Symptoms: Symptoms are mostly engine misfiring, visible droplets in the fuel, and unexplained rust in the filter and tank.
Solution: In this case, the diesel filtration system will remove the free water through separation and capture tiny water droplets with advanced coalescers. - Dirt and debris
The Problem: As we mentioned earlier, diesel tanks accumulate dirt, dust or rust particles. In no time, this will wear out injectors and pumps, reduce combustion efficiency, and finally increase maintenance costs.
Signs: To check if it's dirt and debris, look for the common signs like black smoke from the exhaust, the start is hard or rough and you can see visible dirt in drained fuel samples.
Solution: In this case, the Njord Filtration system will capture particles down to a few microns with its multi-stage filter feature. Apart from that, it will also protect the sensitive engine components so fuel combustion is clean and efficient. - Fuel Oxidation and Sludge Formation
The Problem: Diesel fuel degrades over time, especially if it's stored for months or years, because oxygen exposure causes gum and varnish formation. In worst cases, it will also promote sludge growth at the bottom of the tanks, reducing the energy content of the fuel.
Signs: If you notice the diesel fuel is darkened, cloudy, sediment is visible at the bottom of the tanks, and combustion is poor with black exhaust smoke, then that means oxidation has started!
Solution: Here, the diesel filtration system will continuously circulate and clean fuel, prevent sludge buildup, and remove deposits to restore fuel usability. - Vapor and air contamination
The problem: In our final most common issue, we have air entering the fuel systems during the transfer, or maybe just through air leaks. However, this can lead to vapor bubbles in the fuel lines, provide inconsistent fuel pressure, and cause the engine to shut down abruptly due to misfires.
Signs: The signs of air contamination include hard starting, fluctuating RPMs, and stalling during operation.
Solution: In this case, a diesel filtration system will not just remove the entrained air and vapor during the process of filtration, but also ensure that the fuel pressure is stable while also making sure that the generators and engines are running smoothly.
Bottom Line
When you choose Njord Filtration for fuel filtration, you select a system that offers features like automation, advanced separation, and so much more. The main agenda is to have clean and pure fuel, so that whether it is for production machinery or backup electricity generators, they operate without any delay. All you need to do is invest in the right filtration system and you are good to go.
Have queries? Get in touch with us .
Diesel Generator Failure in Data Centers: How Fuel Filtration Can Prevent It?
Most people think of data centers as highly controlled environments—full of blinking lights, air conditioning, and redundant systems designed to keep everything running no matter what. But there’s one common weak spot that gets overlooked far too often: fuel quality in the backup generators.
In 2025, research indicates that over 90% of medium and large enterprises report losses exceeding $300,000 per hour of downtime. In high-risk environments like data centers, that makes backup power absolutely non-negotiable. And yet, generators still fail frequently. One of the top reasons? Dirty, degraded, or contaminated diesel fuel.
Let’s talk about why it happens, what it costs, and how fuel polishing in a data center can keep your data center out of downtime.
Why Generators Fail?
Diesel generators are critical for data centers. When the grid goes down, they’re expected to kick in within seconds and carry the full load without hesitation. However, diesel fuel isn’t static, it changes over time. And that’s where the problems start.
Water contamination is one of the primary reasons that enters tanks through condensation or poor seals. Once it’s there, it creates the perfect environment for microbial growth—what some technicians call “diesel bug.” The byproduct is sludge. Sludge clogs fuel filters and lines. That alone can stop a generator from running.
Particles and sediment build up over time as well—rust from tank walls, dust from air ingress, and other contaminants that settle and spread. And then there’s oxidation, which happens when diesel ages. It thickens and breaks down, turning gummy and unstable.
All of these issues can lead to something you never want to deal with in a crisis: your generator failing to start, or worse, shutting down mid-run.
The High Cost of a “Small” Problem
This isn’t just about inconvenience. It’s about real business impact. A recent study found that 54% of major data center outages in 2025 resulted in losses exceeding $100,000, with nearly one in five exceeding the $1 million mark.
And many of those were caused not by storms or hardware faults—but by failed generators that hadn’t been properly maintained, or had been running on contaminated fuel. It’s not hard to see the pattern: you can have the best generator money can buy, but if the fuel feeding it is compromised, the whole system is at risk.
How Fuel Filtration Solves the Problem?
Fuel filtration—especially when paired with an efficient fuel polishing system—helps ensure the diesel in your tanks stays clean, dry, and ready to use.
Here’s what a good filtration system actually does:
- Removes water before microbial growth or corrosion happens
- Traps particulates before they reach engine components
- Circulates and filters stored fuel on a regular schedule
- Extends the usable life of diesel so you’re not wasting fuel or risking poor performance
With the right setup, you’re not just fixing problems—you’re preventing them. And in a world where the average cost of a serious outage is so high, prevention becomes more essential.
How to get started in your facility?
If you’re responsible for a data center, here are a few practical steps you can take:
- Test your stored diesel fuel regularly – Contamination often goes unnoticed until the generator fails. Don’t wait that long.
- Invest in a quality fuel filtration or polishing system – It pays for itself the first time your generator starts up flawlessly during a power cut.
- Include filtration into your maintenance routine – It’s not just about equipment; fuel needs the clean-up, too.
- Train your team – Ensure that the facilities staff and operators understand how fuel degradation works and how to identify warning signs.
The bottom line
Even if you’ve got the best backup generator, it can’t help if the fuel running it is unstable or full of sludge. Fuel filtration isn’t just a technical upgrade—it’s a critical part of protecting uptime and avoiding costly outages. If your data center relies on diesel backup power—and most do—it’s worth asking yourself a simple question: Is your fuel as ready as your equipment? If you’re not sure, it’s time to find out.
Contact Njord Filtration today to learn how the best fuel polishing system for data centers can keep your generators running smoothly when it matters most.Is Dirty Fuel Silently Damaging Your Fleet's Engines?
Running a fleet is a challenging job that involves juggling schedules, fuel costs, maintenance, and ensuring every truck operates smoothly without a hitch. The last thing you need is an engine acting up or a truck breaking down unexpectedly. But here's the thing—a lot of those issues might be coming from something most people never think about: dirty fuel.
Even if you're getting your fuel from a reliable source, it doesn't stay clean forever. Over time, things build up—water, gunk, even microbes—and start causing real problems. There's a simple fix: fuel polishing .
What's Dirty Fuel Exactly?
It sounds odd, but fuel can go "bad" just sitting in your tanks. Here's what tends to sneak in:
- Dirt and debris – These clog up your filters and make engines work harder than they need to.
- Water – Usually from condensation. It can cause rust in your tank and mess with fuel quality.
- Microbes – Bacteria and fungi actually grow in fuel, especially when water's present.
- Sludge – All the above builds up into thick, sticky gunk that kills performance.
If your trucks are acting sluggish, going through filters too fast, or you're noticing more breakdowns than usual, your fuel could be the problem.
So What's Fuel Polishing?
Fuel polishing is just a smarter way to clean up your fuel before it reaches the engine. Think of it like giving your fuel a deep clean: Here is what a fuel polisher does-
- Removes the dirt and sludge
- Remove the water
- And in many cases, even kill off bacteria or fungi.
- Then, the fuel gets circulated and cleaned multiple times.
By the end, what goes back into your system is clean, healthy fuel that your engines will thank you for.
Why Is This Important?
Because clean fuel means fewer headaches. Here's what you really get-
- Less downtime – No one likes dealing with breakdowns in the middle of a route.
- Lower repair costs – Clean fuel means fewer clogged injectors and filters.
- Better fuel mileage – Your engines run more efficiently with clean fuel.
- Longer engine life – You're protecting one of your fleet's biggest investments.
- Cleaner emissions – Helps keep you compliant and a little more eco-friendly.
The bottom line
At Njord Filtration, we make fuel polishing systems designed for fleet managers who just want their trucks running without all the drama. Our systems are fast, simple to use, and they work. If you're tired of engine issues or high maintenance costs, give your fuel some attention. A little polishing goes a long way. Let's keep your trucks moving and your costs down.
Check out our fuel polishing systems today—and see the difference clean fuel can make.Clean Fuel on the Go: The Advantages of a Portable Fuel Polishing System
If you manage any kind of equipment that runs on stored diesel fuel, then you must also know that dirty fuel can be a big headache. Over time, any fuel tank can get contaminated with water and a thick sludge that can clog your engines. Cleaning out these tanks can be a very difficult and messy job. But there is a smart and simple solution: the portable fuel polishing system which brings the entire fuel cleaning process directly to your tank wherever it is.
Why is a Mobile Cleaning System a Good Idea?
The biggest reason to use a mobile system is that it is just so much easier. With a portable unit, you do not have to go through the trouble of pumping out all of your dirty fuel and moving it to another location to be cleaned. The machine comes right to your job site, boat, or building, which saves you a lot of time, money and hard work. It takes a big job and makes it so much simpler.
A mobile diesel cleaning unit is also very flexible. A single system can be used to clean a lot of different fuel tanks all at one location. For example, you can clean the tanks of all the heavy machines on a construction site. Or, you can easily move it to a totally different location like servicing a fleet of trucks at your main yard.
What Does a Portable System Do?
This system is designed to remove all the bad stuff from your fuel and leave it in a great condition. Here’s what all it does:
- It Removes Water: The system’s first and most important job is to pull the fuel from the bottom of your tank and run it through a water separator. This removes all of the water which is the main troublemaker that causes most fuel problems. Getting the water out of the tank stops new bacteria and fungi from growing.
- It Filters Out Dirt: After the water is gone, the fuel is then pushed through a series of very fine filters. These filters are made to catch and remove all the sludge, rust, and dirt that can clog up your engine’s filters and injectors. This is the main part of the diesel fuel restoration process.
- It Works on A Lot of Tanks: A portable system comes with its own pumps and long horses. This means it can be quickly and easily connected to a lot of different kinds of fuel tanks. It can be used on everything from the fuel tanks on your heavy equipment to the large backup generator tanks for a building.
- It Cleans the Whole Tank: This is much more than just a simple filtering job. The process of on-site fuel polishing circulates the entire amount of fuel in your tank at a high speed. This strong flow cleans both the fuel itself and also washed down the inside walls of the tank at the same time.
(Also Read: Fuel Maintenance Systems: Protecting Your Investment and Reducing Downtime)
How are These Systems Used in Different Industries?
These mobile systems are useful for many kinds of businesses:
- For Construction Sites: A single portable fuel polishing system can be moved around a large job site from one machine to the next. It can be used to clean the fuel tanks of all your heavy equipment like your excavators and bulldozers. This helps to stop unexpected engine problems that can cause downtime.
- For Marinas and Boats: Many boats sit for long periods of time which allows water to get into their fuel tanks. These systems are a great way to clean out a boat's fuel tank before the start of a new season. This makes sure that the boat's engine will be ready to go.
- For Backup Generators: A lot of important buildings like hospitals or data centers have large backup generators for emergencies. The fuel in these tanks can sit for years and go bad. A portable system is the best way to make sure that the fuel is clean and ready to go when it is needed the most.
Moving Forward
A portable fuel polishing system is a flexible and good way to clean your stored diesel fuel right where it is. It is also a great tool for any business that needs clean fuel to keep its important machinery running well. Visit our website to learn more about our mobile fuel polishing systems at Njord Filteration.
Feel free to contact us at Diese E-Mail-Adresse ist vor Spambots geschützt! Zur Anzeige muss JavaScript eingeschaltet sein! if you need fuel tank cleaning services at your location and you don't know what to do.
Fuel Testing and Fuel Polishing: Their Differences and Importance
Whether in hospitals, data centres, offshore platforms, or industrial facilities, negotiating with a reliable fuel quality is a big NO! Because even a moment of failure during a power outage could cost money, time, and even lives. When it comes to emergency backup systems, many management systems confuse between fuel testing and Fuel Polishing for emergency systems. Well, this is why experts at Njord Filtration will help you differentiate between the two, so that, whether big or small, no industry has to deal with unnecessary consequences.
In this blog, you will find out more about the difference, what their benefits are, and how a balance between both can save your money and time. So, keep reading.
Fuel Testing Vs Fuel Polishing
- Fuel Testing
Now, simply put, Fuel testing is the checkup for your stored fuel. It involves taking samples from storage tanks and analysing them to detect signs of contamination, degradation or microbial growth. The purpose is multifaceted, but it significantly identifies contamination, such as water, sludge, and microbes, while also measuring fuel stability and degradation over time, and detecting corrosion risks in storage tanks. This process typically assesses compliance with fuel quality standards like ISO 4406.
In most cases, fuel testing services check sediment and sludge levels, microbial contamination like bacteria and fungi, flash point and pour point, particulate count, fuel oxidation and acid number, and cloud point and density.
(Also read from our previous blogs: The Importance of a Water Separator in Diesel Fuel Polishing: Expert Advice) - Fuel Polishing
On the other hand, Fuel Polishing is the treatment that removes contaminants from stored fuel. One can say that while fuel testing is the diagnosis, polishing is the cure of the problem. It’s a physical cleaning process that filters out water, debris, microbial sludge and any other harmful substances from the fuel.
Upon doing this, you are not only able to restore fuel to usable condition, but also prevent injector clogging and equipment failure, extend the life of the fuel, reduce emissions and carbon buildup, and finally, allow it to eliminate the need to replace fuel entirely considering this clean fuel is good to go for another 4-6 months based on the environment or the quantity of usage.
Do you need both?
The answer is yes. Assuming fuel polishing is enough for the generators to work efficiently would be wrong and could lead to breakdowns, as we were discussing before.
The following will tell you how a balance of both can benefit you:
- Test First, Then Treat
You wouldn’t start treatment without testing first, right? In the same way, as we said, testing identifies the problem, and polishing fixes it. - Fuel Can Look Clean But Still Be Contaminated
Visually inspecting diesel fuel is not enough, as it may look clear. But in most cases, it still contains unnecessary stuff like dissolved water, invisible microbes and tiny particulates. So when you get the fuel checked, you can also check the condition of the fuel. - Polishing Alone Can Mask Bigger Issues
Yes, fuel polishing can clean and filter out debris, but if you do it without testing, you might miss other factors like tank corrosion, fuel instability and microbial growth. - Dirty Fuel is the reason behind Generator Failure
Many Original Equipment Manufacturers have stated that more than 80% of generator failures are due to contaminated fuel, which causes clogged injectors, sludge in filters and incomplete combustion.
When to schedule maintenance?
Typically, industries should follow this fuel maintenance cycle:
- First month: Fuel testing
- Months 1-2: Fuel polishing if required
- Month 6: Retest fuel quality
- Month 12: Test again and polish if degradation is seen
If you are in an offshore location, consider pre-Storm Season re-testing and polishing, unless maintenance was done recently.
Bottom Line
When it comes to fuel testing and fuel polishing for emergency systems, Njord Filtration has been the most reliable choice globally. Starting from the healthcare centres to industries, our maintenance tool has always offered advanced technology that not just increases the lifespan of the generators but also saves your money for a longer period.
Need expert advice? Get in touch with us here.