AI and advanced control systems: key to scaling the synthetic fuels industry?
As Europe’s 2% SAF mandate comes into force, demand for sustainable fuels is accelerating. Avioxx is one of the only UK companies producing synthetic Fischer–Tropsch crude in real time demonstrating a clear pathway from waste to jet fuel. At the heart of this capability is the software and digital infrastructure that drives our reactors and systems.
Last month, Avioxx commissioned a major upgrade to its micro-pilot facility in Runcorn, Cheshire: a fully centralised, AI-driven process control system with remote access and 24/7 monitoring. This milestone lays the groundwork for scaling our first-of-a-kind waste-to-fuel technology to meet surging demand from aviation fuel suppliers and contribute meaningfully to Net Zero targets.
Meeting demand with innovation
Global air travel demand reached record highs in 2025. Despite economic and environmental headwinds, passenger appetite remains strong, and with it, the urgency for clean fuels. Avioxx is answering that challenge. Our SAF process is carbon efficient and uses waste feedstocks that would otherwise end up in landfill or incineration.
Next-generation control and data systems
At the core of our operations is AVEVA InTouch 2023, a high-performance HMI platform providing real-time visibility across the plant. Replacing isolated and manual systems, the upgraded infrastructure now delivers seamless data flow, control, and monitoring across all units.
A high-capacity central server tracks over 1,000 real-time tags and millions of datapoints, from gas flows and reactor temperatures to transfer line feedback. These datasets are processed using AI and machine learning, enabling predictive insights, automated reporting, and continuous process optimisation.
We’ve also integrated Kepware’s KEPServerEX middleware to ensure interoperability across legacy and modern PLC systems. Secure remote access now allows for global demonstrations, diagnostics, and safety oversight, ensuring consistent fuel production, from anywhere in the world.
Clean data for clean fuel
Our synthetic crude is ultra-clean, and the same must be true of our data. To support First-of-a-Kind (FOAK) plant development, we’ve built a clean, reliable digital infrastructure to power accurate simulation, scale-up, and control. The upcoming integration of our X25 reactor into the AVEVA platform will mark another step forward in validating Avioxx’s system at scale.
Digital-first and ready to grow
Avioxx’s strategic priority is scaling production to meet rising airline demand and help fulfil the aviation sector’s SAF obligations. Our patented process benefits from a digital-first architecture, including an automated, AI-driven feedback loop that adapts to feedstock variability in real time.
Advanced analytics and predictive maintenance modules are being added to uphold the high standards of operational integrity, transparency, and quality for which Avioxx is becoming known. We welcome input from across the aviation and fuels sector and invite stakeholders to experience our live control system demonstration.
Dynamic reactor control
Synthetic fuel production requires precise control of complex and sensitive reactions. Avioxx will deploy dynamic reactor control across its Fischer–Tropsch and gasification units, enabling real-time adjustments based on continuous data feedback. AI models will analyse parameters such as feedstock composition, reactor temperature profiles, and catalyst activity to make autonomous adjustments, ensuring fuel quality and operational efficiency.
This approach reduces downtime, increases conversion yields, and supports consistent, steady-state operations, even when feedstock conditions vary. It is a vital enabler for scaling production while maintaining traceability and performance.
A word from our CEO
“My background is tech. Fuel is undergoing radical change, driven by the climate crisis, decades of underinvestment, and a new wave of enabling technologies. By putting software and AI at the core of our system, and leveraging the latest reactor designs, we’re positioning Avioxx to leapfrog the incumbents.” - Chris Hancock, CEO, Avioxx
With its unique combination of technology, talent, and purpose, Avioxx is ready to lead the future of sustainable fuel. To learn more or request a demo, get in touch: info@avioxx.com.