Additives vs. Kerosene: Don’t Pick the Wrong Winter Fix

As winter settles in, diesel gelling becomes a real concern for fleets across North America. When temperatures drop, wax crystals form, filters clog, equipment shut down, and suddenly you're facing delays, emergency calls, and unexpected costs. That's why it's worth planning ahead for strategies that keep diesel moving in harsh weather. The question is: what works best today, kerosene blends or winter additives?

In today's article we'll walk through the differences, explore when each option is necessary, and highlight how modern fuel strategies can save money while keeping your fleet operating smoothly.

Why Diesel Gels - and Why It Matters

Diesel contains paraffin. When it gets cold, this paraffin crystallizes, thickens the fuel, and eventually blocks filters. Once fuel can't pass through those filters, engines stall. So, protecting your fuel's Cold Filter Plugging Point (CFPP) is key.

Historically, fleets relied heavily on kerosene. But today's ULSD behaves differently, and newer solutions, especially winter additives, often work better, cost less, and protect engines more effectively.

Kerosene Blends: The Traditional Winter Fix

Blending kerosene (#1 diesel) into #2 diesel has been common for decades. Fleets often use blends like 90/10, 70/30, or even 50/50 to ensure winter operability. It works because kerosene lowers CFPP; every 10% blend usually gives you about 3°F of protection.

However, Kerosene comes with trade-offs that can impact performance, cost, and equipment longevity. Because kerosene contains roughly 7.5% fewer BTUs than diesel, it reduces engine power and fuel economy. Lower cetane levels also mean harder cold starts, longer warm-ups, and even white smoke. On top of that, kerosene is "drier," offering less lubricity. Over time, this can increase wear on pumps, seals, and injectors.

Then there's the price. It almost always costs more than #2 diesel and blending 20-50% kerosene raises your fuel cost without giving you dramatic winter protection in return.

Winter Additives: The Modern, More Effective Solution

Today's diesel responds far better to engineered winter additives, such as Mansfield's Arsenal ColdPro. A high-quality winter additive can improve cold-flow operability by 15-20°F. Additives don't reduce fuel efficiency or engine power because they don't dilute BTU content. They also help maintain lubricity, which protects pumps and injectors, something kerosene cannot do. Many additives also include de-icers to help control water and prevent ice formation in the fuel system. Another advantage? Additives are almost always more cost-effective. Instead of replacing 20-50% of your fuel with a more expensive product, you're treating your fuel with less expensive - but reliable solution.

When Should You Use Kerosene?

Even the best additive has its limits. When temperatures plunge to extreme lows, such as -20°F in places like Minnesota, kerosene becomes essential.

Here's the key: kerosene should be used strategically; not all winter long. A smarter strategy would be to use winter additives regularly and reserve heavier kerosene blends for extreme cold snaps. In most cases, an 80/20 or 70/30 blend combined with a winter additive is sufficient. Save the 50/50 blend for the days when the forecast becomes dangerously cold. This approach lowers costs while still protecting engines reliably.

Reduce Costs and Improve Winter Performance

Just as planning your fleet's routes is crucial for efficiency, properly preparing your fuel for winter is essential for avoiding costly breakdowns. Mansfield's Arsenal ColdPRO is a program to improve your fuel's cold-weather performance, offering consistent and accurate treatments, minimizing kerosene cost, and performing nationwide fuel testing.

With the right strategy in place, you can keep your fleet running smoothly throughout the winter season, regardless of where you operate. If you haven't already, contact Mansfield to learn more about Arsenal ColdPro. Don't wait; contact us today to secure a worry-free winter for your fuel needs.