Noxdown is a fast-growing manufacturer of AdBlue®, supplying haulage firms and agricultural customers across the UK. Founder Rob Vallis shares how he built the business “from one man and a van” into a thriving production operation - supported by investment in Adelphi Masterfil filling technology.
At a Glance
The Product – AdBlue®
AdBlue® is a widely used emissions-reduction fluid injected into the exhaust systems of diesel commercial vehicles, agricultural machinery and increasingly passenger cars. Harmful exhaust gases react with ammonia in the AdBlue® and the vehicle’s catalytic converter, producing nitrogen and water - two harmless by-products - significantly reducing emissions.
The Customer Base
Noxdown primarily supplies haulage firms and farmers. Demand peaks seasonally, and during March 2022 alone, the business distributed 2 million litres of AdBlue®.
“It just goes!” says Rob.
The Containers
Noxdown works with volumes ranging from 20L containers to 26,000L tankers. This case study focuses on the production of 20L containers.
From Manual Filling to Precision Automation
“I met Andy and became aware of Adelphi Masterfil around four years ago,” Rob recalls.
“At the time we were filling from a basic tap system - messy and inaccurate, as the fill volume was detected by eye.”
As output demands increased, the manual process became unsustainable. To improve accuracy, cleanliness and efficiency, Rob invested in an Adelphi Masterfil S5000-S semi-automatic twin-head filling machine.
Improved Accuracy Prevents Waste and Protects Reputation
The new filling machine prevents costly fill variations by eliminating both overfilling and underfilling.
Rob explains that underfilling can be especially damaging:
“The new machine prevents customers ever feeling short-changed!”
A 10,000L supply tank feeds the S5000-S filler, enabling Noxdown to fill approximately 12 pallets per day, each pallet containing 32 × 20L containers - equating to over 7,500L filled daily.
Faster Filling and Reduced Labour Requirements
To counteract the foaming nature of AdBlue®, the machine is fitted with a rise-while-fill nozzle option, maximising throughput speed while maintaining accuracy.
A cap basket has also been added, allowing one operator to manage the entire filling process - capping two containers while the next two are filling - improving labour efficiency.
Built-In Flexibility for Future Growth
Rob plans to introduce 10L and 15L containers to meet customers’ manual handling requirements. Thanks to the multi-shot functionality of the S5000-S, all container sizes can be filled on a single machine, using multiples of 5L.
Simple Setup and Rapid Deployment
Was the machine easy to install and operate?
“It’s straightforward to set up and use - it does what it says on the tin,” says Rob.
Because the S5000-S is a stock machine, Noxdown also benefited from a significantly reduced lead time, compared with industry norms. Adelphi Masterfil aims to keep machines in stock wherever possible to minimise customer downtime.
Service Technician Steve Logan carried out minor troubleshooting during installation and provided comprehensive operator training, including container size changeovers, leaving the team confident to use the machine immediately.
Shared Values and Certified Quality
Both Noxdown and Adelphi Masterfil operate under stringent ISO-certified quality standards.
“Every product that leaves our factory is of certified quality,” promises Noxdown.
Working with like-minded partners ensures consistency, reliability and confidence throughout the supply chain.
Measurable Success: The Key Numbers
- Workforce growth from 1 to 10 employees
- Storage capacity doubled from 3 to 6 bulk tanks
- Facility expansion from 2,500 sq.m to 11,000 sq.m
- Plans underway for a new 20,000 sq.m site with 2 acres of land
Demand for Noxdown’s AdBlue® continues to rise rapidly, and the business is well positioned to meet - and exceed - future growth targets.
The Verdict
“There are certain people you’re happy to deal with, and some that you’re not - Andy and Adelphi are still here, which says it all!”
Rob Vallis, Owner, Noxdown
