Coulson Aviation tackles fuel contamination with real-time onboard monitoring system
November 4, 2025
Every pilot trusts their aircraft to the last drop of fuel. But what if that fuel isn’t clean?
It’s a thought that rarely crosses anyone’s mind until something goes wrong, until a filter clogs mid-air or an engine coughs to a halt.
Across both civil and military aviation, contamination from water, rust, or microbial growth has quietly caused costly groundings, flight delays, and, in some cases, crashes.
To take that risk off the table, Coulson Aviation, one of the world’s leading aerial firefighting companies, has developed SafeFuel, an onboard system that checks fuel quality in real time as it’s being loaded into the aircraft.
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A growing global concern as contaminated fuel threatens flight safety
Fuel contamination is one of aviation’s least visible hazards, but also one of its most stubborn. Over the years, accident investigators have traced numerous incidents back to fuel that was compromised long before the aircraft ever took off.
Just this October, the US Navy opened an inquiry into whether “bad fuel” was responsible for two aircraft crashing off the carrier USS Nimitz.
Even in commercial aviation, where quality checks are exhaustive, cases of microbial growth and water-laden Jet A have grounded entire fleets and cost operators millions.
For Coulson Aviation, whose aircraft fly punishing firefighting missions in remote regions, the issue is never theoretical.
“We’ve designed aircraft to survive almost any emergency,” said Britt Coulson, President and COO of Coulson Aviation. “But none of that matters if the fuel itself isn’t safe. When just a few gallons of off-spec fuel can bring down a $100-million aircraft, it’s time to close that gap. SafeFuel does exactly that.”
How contamination happens, and why it’s getting worse
Jet fuel contamination takes many forms. It might come from rust and scale particles shed by ageing storage tanks, or from water sneaking in through humidity and condensation.
Once water enters the system, it creates the ideal environment for microbial growth, especially for the fungus Hormoconis resinae, known to corrode tanks and clog filters with a slime-like biofilm.
A newer challenge lies in cross-contamination from biodiesel and renewable energy supply chains. Even trace amounts of FAME (Fatty Acid Methyl Ester) can push jet fuel out of specification.
With aviation shifting towards Sustainable Aviation Fuels (SAF) and higher bio-content blends, the problem is growing. These new fuels are cleaner for the planet, but friendlier to microbes.
SafeFuel: real-time jet fuel contamination monitoring onboard aircraft
Developed and patented by Coulson’s in-house engineers, SafeFuel is designed to act before problems ever start. Installed directly in an aircraft’s refuelling manifold, it continuously monitors incoming fuel for particulates, water, and chemical deviations.
If it detects anything off-spec, the system warns the crew instantly, and can even halt the flow before contaminated fuel reaches the tanks. Every refuelling session is digitally logged, providing operators with a verified audit trail accessible to regulators and manufacturers alike.
For a company that operates in extreme environments, from the Canadian wilderness to Australian bushfires, SafeFuel isn’t just about innovation; it’s about peace of mind.
The high cost of contaminated aviation fuel
Fuel contamination doesn’t just threaten safety: it quietly eats into aviation’s bottom line. Microbial contamination alone can sideline an aircraft for weeks as tanks are drained, filters replaced, and lines flushed.
A single incident can cost tens of thousands in repairs and millions more in downtime. Yet, most detection systems remain reactive, finding contamination only after the damage has already occurred.
That’s beginning to change. On the ground, companies like Conidia Bioscience, led by Paul Hicks, are advancing rapid-testing solutions. Their FUELSTAT One system can detect microbial contamination in minutes, with no laboratory setup required.
“Changing fuel compositions, especially with sustainable blends, are creating new microbial challenges,” Hicks said. “With FUELSTAT One, you can find that contamination early and stop it before it turns into a maintenance nightmare.”
Together, SafeFuel and FUELSTAT One represent a new mindset, one that treats fuel verification as part of safety, not just maintenance.
Why preventing fuel contamination matters more than ever
As air traffic expands across Asia, Africa, and Latin America, refuelling operations are increasingly decentralised and unpredictable. Even the best-maintained aircraft are only as safe as the fuel they’re fed.
Nigerian Max Air Claims Contaminated Fuel Supply Led to Boeing B737 Operations Suspension ; Fuel Provider Octavus has Denied the Allegations.
— FL360aero (@fl360aero) July 21, 2023
Read More : https://t.co/NhkQonShsF#aircraft #aviation #safety #airlines pic.twitter.com/rdaccj4O0t
SafeFuel’s real-time data gives operators confidence that what’s going into their tanks is exactly what should be, wherever in the world they are. It turns an old, manual process into a live safety system built directly into the aircraft.
A new layer of trust in aviation fuel safety
For all the sensors and systems that track aircraft health today, fuel has been the one element left largely unmonitored once onboard. SafeFuel changes that.
By providing continuous verification at the point of refuelling, it adds a vital layer of trust to aviation, one that could prevent accidents, save lives, and redefine how the industry thinks about flight safety.
“As the industry moves toward sustainable fuels and increasingly complex supply chains,” Coulson said, “being able to verify fuel purity instantly won’t just be useful; it’ll be essential.”
