UCO to SAF

Case Study:

Enabling an ISCC-Certified Supply Chain from Waste Oil Collection to Sustainable Aviation Fuel

Overview

A multi-site Australian waste oil collection and processing company sought to position itself within the Sustainable Aviation Fuel (SAF) supply chain, requiring ISCC certification to access international markets and downstream fuel producers.

The organisation managed a complex upstream network, including over 5,000 Points of Origin (PoO), with operations spanning collection, filtration, and dispatch across NSW, QLD, and VIC.

While operationally established, the business lacked an integrated certification framework to connect its activities to ISCC-certified SAF production pathways.

The Challenge

The primary challenge was bridging the gap between waste collection operations and certified aviation fuel supply chains.

Key risks included:

Absence of an end-to-end traceability system linking feedstock to SAF production

Inconsistent mass balance application across multiple sites

Limited control over sustainability documentation required for downstream certification

Complex management of thousands of non-certified Points of Origin

Risk of failing to meet ISCC CORSIA requirements for aviation fuel eligibility

Without a structured approach, the business could not reliably participate in SAF markets or supply certified material to fuel producers.

The Approach

The engagement focused on structuring a certification-ready supply chain, aligning upstream collection with downstream aviation fuel requirements under ISCC.

Supply Chain Integration

A framework was established to connect feedstock collection directly to SAF pathways, ensuring:

Clear classification and verification of Points of Origin

Segregation and control of eligible waste-based feedstocks

Alignment with ISCC sustainability criteria for aviation fuels

Mass Balance Alignment

A unified monthly mass balance system was implemented across all operational sites, ensuring:

Consistent accounting of input/output material flows

Integration of operational losses (~5%)

Compatibility with downstream SAF certification requirements

End-to-End Traceability

A complete traceability system was developed to support certification through the full value chain:

Collection → Processing → Dispatch → Fuel Production

This included:

Sustainability Declarations

Incoming material verification

Outgoing certified product documentation

Multi-Site Operational Control

Operations were aligned across all locations, with defined roles:

NSW as the central commercial and dispatch control hub

QLD and VIC as dependent collecting and processing sites

This ensured consistency in reporting, compliance, and certification data flow.

Compliance & Risk Management

Key systems were strengthened to ensure audit readiness:

Internal audit and verification processes

Supplier approval and monitoring

Documentation and record control

All gaps were addressed through targeted corrective actions and structured improvements.

The Outcome

The project delivered a fully structured, ISCC-compliant supply chain aligned with Sustainable Aviation Fuel requirements, enabling:

End-to-end traceability from waste oil collection to SAF production

A consistent and auditable mass balance framework

Control of sustainable feedstock in line with ISCC CORSIA requirements

Multi-site operational alignment and certification readiness

Commercial Impact

Enabled participation in the Sustainable Aviation Fuel (SAF) value chain

Increased the commercial value of waste-derived feedstock

Positioned the business as a reliable upstream supplier to certified fuel producers

Reduced certification risk and accelerated market entry

Key Insight

Sustainable Aviation Fuel supply chains are only as strong as their upstream traceability and certification structure. Without this, even well-run operations cannot access high-value markets.

About

Mason Ali works with waste, recycling, and renewable energy businesses to structure certification-ready supply chains—connecting feedstock, compliance frameworks, and commercial outcomes across global markets.