Stay Ahead of the DEF Shortages in 2025: What Fleet Managers & Diesel Mechanics Need to Know

With major plant maintenance and a facility closure on the horizon, the Diesel Exhaust Fluid (DEF) market is bracing for a period of disruption and rising costs. This activity is already driving up spot prices and sparking concerns about product availability through the rest of 2025.

DEF plays a vital role in reducing emissions in diesel-powered engines. Through the Selective Catalytic Reduction (SCR) process, DEF helps convert harmful nitrogen oxide (NOx) emissions into harmless nitrogen and water vapor—helping fleets meet federal emissions standards.

For fleet managers, diesel mechanics, and other procurement professionals in the transportation industry, it’s important to stay up-to-date on fluid trends. Let’s explore what’s causing DEF shortages, how the market is evolving, and what your fleet can do to stay ahead.

Is There a DEF Shortage in 2025?

Yes, there are widely anticipated DEF shortages expected to begin in summer 2025 and likely to extend into fall, if not beyond. Several major plants responsible for the bulk of DEF production in the United States are undergoing scheduled maintenance or facing operational uncertainty, significantly reducing overall output capacity during the coming months.

Maintenance and Closures at Specific Facilities

To grasp the full impact of upcoming DEF shortages, it’s important to understand which production facilities are going offline—and when. The following plants are scheduled for maintenance or facing operational uncertainty:

Planned Maintenance

• Donaldsonville Complex (CF Industries): As the largest DEF production site in the country, its scheduled 6-8-week maintenance period starting this month is already tightening supply. Anticipating limited output, CF has elevated spot prices across its distribution network, a trend likely to continue throughout the duration of the maintenance.
• Woodward & Yazoo City Plants (CF Industries): Maintenance at these facilities is scheduled for August and September.
• Geismar Facility (Nutrien): This site is also undergoing a scheduled turnaround during the summer months.
• Enid Plant: Buyers have been advised that Enid will enter maintenance in June.
• Beulah Plant: Beulah is expected to undergo maintenance between August and September.

Upcoming Closure

• St. Helens Plant (Dyno Nobel): Originally scheduled for maintenance, the plan has been scrapped due to the facility’s anticipated closure in early 2026. With aging infrastructure and no upgrades planned, production issues could arise even before its official shutdown—creating another layer of uncertainty in an already delicate market.
  

Demand for DEF Continues to Increase

Even as supply faces serious challenges, demand for DEF is climbing and shows no signs of slowing. The global DEF market is projected to grow at a robust 7.9% compound annual growth rate (CAGR) between 2024 and 2030, reaching an estimated $61.56 billion by the end of the decade. In North America specifically, the DEF market is projected to grow from $15 billion to $22 billion by 2027, driven by an 8% annual growth rate.

There’s no single reason behind this surge—rather, it’s the result of a combination of regulatory pressures, evolving industry needs, and infrastructure improvements. Together, these factors are fueling steady growth in DEF consumption across nearly every diesel-dependent sector. Let’s walk through them in depth.

Stricter Emissions Standards

Government regulations targeting NOx emissions have become more stringent, especially for heavy-duty diesel engines. To meet these mandates, fleets rely on SCR systems, which in turn require a consistent supply of DEF to operate effectively. The upcoming EPA low-NOx regulations set for 2027 will require even more sophisticated engine systems, likely incorporating dual SCR units and cylinder deactivation—both of which will dramatically increase DEF consumption.

Cross-Industry Expansion

While over-the-road trucking remains the primary consumer of DEF, other sectors such as construction, agriculture, and marine shipping are ramping up their usage as they retrofit and upgrade equipment to meet emissions standards. With infrastructure and real estate development booming, these sectors are contributing significantly to the rising demand.

Infrastructure Growth

Access to DEF is also improving. More DEF pumps and bulk delivery services are available than ever before, enabling fleets to procure DEF more conveniently. But as vehicle age and mileage rise nationwide, so too does the volume of DEF required to keep fleets running smoothly.

Challenges Contributing to DEF Shortages

While demand for DEF continues to rise, several challenges threaten to disrupt the market’s stability in the near term. One of the most pressing concerns is the lack of new domestic urea production facilities. Urea is a nitrogen-containing compound used to manufacture DEF. Without additional capacity coming online, the U.S. may become increasingly dependent on imported urea, which introduces risks tied to global supply chains.

Compounding the issue, North American urea production is projected to fall short by approximately 35 million gallons in 2025. This shortfall could significantly affect the availability of DEF, especially during peak usage periods. Although imports from Europe are helping to offset some of the gap, they are not a guaranteed long-term solution.

Looking further ahead, the growing adoption of electric vehicles could eventually reduce DEF demand. But for now, the vast majority of diesel fleets remain reliant on combustion engines and SCR systems to meet emissions standards. Until a broader transition to electric takes place, DEF will remain an essential part of daily operations for most fleets.

What to Expect with DEF Shortages in 2025

If you’re in the business of diesel fleet operations, anticipated DEF shortages in 2025 may have tangible consequences. These will likely include:

• Tighter supply across regions, with regional bottlenecks more likely during high-demand periods.
• Price volatility, as producers increase spot pricing to manage limited output and higher production costs.
• Disrupted supply chains, especially if maintenance delays or production issues extend beyond the anticipated windows.
• Increased competition for inventory, potentially putting smaller operations at risk of running out if procurement isn’t proactive.

How to Stay Prepared with Impending DEF Shortages

Now is the time to get ahead of the curve. With DEF shortages on the horizon, the most effective way to protect your operation is through a proactive procurement strategy paired with strong supplier relationships.

1. Start by stocking up strategically. Don’t wait until your tanks are running low—secure extra inventory now to ensure you're covered during the critical summer and fall months when supply is expected to be tight. Having a buffer on hand can mean the difference between staying operational and facing costly downtime.
2. It’s also essential to keep a close eye on market conditions. Monitoring maintenance schedules at key production facilities, tracking global urea trends, and staying informed about pricing shifts can help you make smarter, more timely purchasing decisions.
3. Partnering with a reliable DEF supplier is equally important. Look for one with a proven track record of consistency, transparent communication, and a robust distribution network that can keep you supplied even during turbulent periods.
4. Finally, don’t overlook the importance of your own storage and inventory systems. Ensure your DEF storage equipment is properly maintained and that your inventory is closely monitored. These steps will help you avoid last-minute DEF shortages and keep your fleet running smoothly, regardless of external supply pressures.

Where to Get DEF Fluid Amid Shortages

When supply tightens, it’s important to rely on trusted partners. Keller-Heartt has been a dedicated ally to the trucking industry for decades and continues to support fleet operators with in-stock, ready-to-ship DEF, even during turbulent times.

We proudly offer BlueDEF, a premium-grade diesel exhaust fluid that meets the highest standards of quality and performance. BlueDEF is ISO 22241 compliant and API certified, meeting or exceeding all OEM specifications. It’s made with ultra-pure synthetic urea and deionized water to ensure peak performance of your SCR systems—reducing the risk of contaminants and system damage. 

Whether you need small containers or bulk deliveries, BlueDEF is available in the quantity and format that fits your fleet’s needs.

Prevent Fleet Downtime From DEF Shortages

DEF shortages don’t have to sideline your operation. With the right strategy and a reputable supplier, you can navigate upcoming disruptions with confidence.

Don’t wait until DEF becomes scarce or expensive—place your DEF order online now or reach out to our team directly. At Keller-Heartt, we’re committed to helping you weather any supply storm, with dependable service and top-tier products that keep your fleet rolling.