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Double Distilled Process
Inside the Science of Sunoco Race Fuel

Explore the technology and team behind the Double Distilled™ process and how Sunoco Race Fuels are designed to deliver the most consistent, high-performance fuel on the track.

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The Double Distilled™ Difference: Purity, Consistency & Performance

Double Distilled™ isn’t a marketing slogan, it’s a scientific differentiator. Standard fuels are distilled and refined for volume output, not precision. Sunoco Race Fuel undergoes a second distillation, purifying the hydrocarbon blend and removing low-energy components and unstable compounds.

This process results in a race fuel that burns cleaner, resists vapor lock, and maximizes combustion efficiency. The outcome? Improved throttle response, lower engine deposits, and more consistent tuning parameters across all motorsport disciplines.

 

NASCAR Fuel Cans
Sunoco Race Fuel Tanks, Truck and Crew

Inside Sunoco’s Marcus Hook Facility

Sunoco Race Fuels are produced in Marcus Hook, Pennsylvania, a facility that represents decades of investment in racing excellence. Unlike generic fuels or blends adapted from street applications, every drop of Sunoco Race Fuel is engineered specifically for performance. The Marcus Hook distillation tower is central to this process, enabling Sunoco to achieve the strictest standards in the racing industry.

This facility is unique in its purpose: to double distill race fuel for maximum purity. Through this advanced process, Sunoco can eliminate variability, improve combustion characteristics, and deliver batch-after-batch reliability that meets the demands of top-tier motorsports.

How Race Fuel
is Made

Race fuel production starts with highly refined hydrocarbon base stocks chosen for volatility, burn profile, and density. These ingredients enter a controlled distillation process at Sunoco’s Marcus Hook facility. The second distillation removes unwanted components to deliver peak consistency.

Post-distillation, additives like antioxidants, detergents, and corrosion inhibitors are introduced. Each fuel is tested to meet precise physical specs. Whether it’s Maximal, 260 GT Plus, or E30-R, every batch reflects meticulous engineering.

 

Why Consistency
Wins Races

One inconsistent drum can derail a race weekend. That’s why Sunoco certifies every fuel batch with tight tolerances for octane, oxygen content, volatility, and more. There is no variance in Sunoco’s process. Racers get exactly what they expect.

This consistency allows teams to build repeatable tuning maps and push engines harder without retuning from batch to batch. When top performers remove variables, Sunoco’s Double Distilled™ technology is the reason why.

 

How Race Fuel
is Made

Race fuel production starts with highly refined hydrocarbon base stocks chosen for volatility, burn profile, and density. These ingredients enter a controlled distillation process at Sunoco’s Marcus Hook facility. The second distillation removes unwanted components to deliver peak consistency.

Post-distillation, additives like antioxidants, detergents, and corrosion inhibitors are introduced. Each fuel is tested to meet precise physical specs. Whether it’s Maximal, 260 GT Plus, or E30-R, every batch reflects meticulous engineering.

Why Consistency
Wins Races

One inconsistent drum can derail a race weekend. That’s why Sunoco certifies every fuel batch with tight tolerances for octane, oxygen content, volatility, and more. There is no variance in Sunoco’s process. Racers get exactly what they expect.

This consistency allows teams to build repeatable tuning maps and push engines harder without retuning from batch to batch. When top performers remove variables, Sunoco’s Double Distilled™ technology is the reason why.

Meet the Technical Team

Sunoco’s reliability is backed by a technical team of specialists, including Olivia Madiraca who has a background in fuel blending and refining. These experts support racers with ethanol compatibility advice, tuning insights, and on-the-ground feedback that improves product development.

Sunoco provides a dedicated tech support line at 1.800.RACE.GAS to assist with product selection and optimization. The team ensures that science supports every performance claim.

 

Sunoco Race Fuel Pit Crew with Fuel Tanks

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Sunoco's Science Frequently Asked Questions

What does Double Distilled™ mean?

Double Distilled™ is a two-stage refining process where Sunoco race fuel undergoes a second distillation to remove low-energy components and unstable compounds. This creates a purer hydrocarbon blend that burns cleaner, resists vapor lock, and delivers more consistent combustion efficiency than standard fuels distilled only once.

Inconsistent fuel creates tuning variability that can ruin race weekends. Sunoco certifies every batch with tight tolerances for octane, oxygen content, and volatility, allowing teams to build repeatable tuning maps and push engines harder without retuning between drums. Eliminating fuel as a variable gives racers a competitive advantage.

All Sunoco Race Fuels are produced at the Marcus Hook facility in Pennsylvania, a dedicated distillation tower used specifically for racing fuel production. Unlike generic fuels adapted from street applications, every batch is engineered exclusively for motorsport performance with strict quality control standards.

 

Sunoco's Marcus Hook facility is purpose-built for double distillation, removing components that compromise performance and stability. This process eliminates variability, improves combustion characteristics, and delivers batch-after-batch reliability. Each fuel is tested post-production to meet precise physical specifications before reaching customers.

Yes. Sunoco maintains a technical team of specialists who provide ethanol compatibility advice, tuning insights, and product selection guidance. Racers can contact the dedicated support line at 1.800.RACE.GAS for expert assistance in optimizing fuel choice and engine performance.

Explore the Double Distilled™ Advantage

Whether you are running quarter miles, circuit laps, or dirt tracks, Sunoco Race Fuels give your engine a cleaner, more consistent platform for performance. From formulation to finish line, it's science that sets Sunoco apart.

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