Extend the life
of the plant.
A £500k+ industrial wash installation should not be scrapped simply because individual pumps, burners, or PLCs are reaching end-of-life. Alkota brownfield engineering delivers targeted refurbishment, automation modernization, and water treatment retrofits on live operational sites.
Phased delivery on live operational sites.
Halting a fleet depot or mining wash bay for weeks is commercially impossible. We engineer upgrade packages with off-site pre-fabrication, factory testing, and planned shift cutovers to protect operational continuity.
Off-Site Skid Fabrication
Pumps, thermal coils, and control cabinets are fully wired and hydrostatic pressure-tested at our facility before site arrival.
Planned Cutover Windows
Mechanical and electrical tie-ins are scheduled during weekend or overnight operational downtime windows.
Retain Sound Civils
We reuse existing concrete wash pads, sumps, and structural buildings while replacing only the worn mechanical plant.
60–75% CAPEX Savings
Targeted subsystem modernization delivers modern performance at a fraction of complete demolition and rebuild costs.
Verified Refurbishment Categories.
High-Pressure Pump Skid Modernization
Replacing obsolete, worn, or low-efficiency pump assemblies with modern triplex ceramic plunger arrays with VSD soft-start control.
PLC & Automation Modernization
Migrating failing relay panels or obsolete PLCs to modern Siemens / Mitsubishi architectures with intuitive touchscreen HMIs.
Variable Speed Drive (VSD) Integration
Soft-starting motors, eliminating mechanical shock on pipework, and ramping pressure on demand to reduce energy consumption.
Closed-Loop Water Recycling Retrofit
Adding media sand filtration and coalescing oil separation to convert direct-discharge wash bays into sustainable, EA-compliant facilities.
High-Efficiency Schedule 80 Thermal Coils
Replacing scaled or burst coils with heavy ASTM A53 Schedule 80 continuous-wound assemblies and modulating gas/diesel burners.
Automated Underbody & Spinner Rigs
Retrofitting automated chassis spray bars and rotating wheel spinners into manual bays to slash vehicle cycle times.
High-Pressure Swivel & Boom Arm Upgrades
Replacing seized 360° booms with Grade 316 stainless steel assemblies and heavy-duty balanced drop lances.
Instrumentation & Sensor Upgrades
Installing optical profiling, ultrasonic level sensors, digital pressure transducers, and flow totalizers.
Safety & Category 4 Interlock Overhauls
Retrofitting dual-channel safety relay loops, light curtains, emergency stop buttons, and automated pressure relief systems.
Sump & Primary De-Silting Enhancements
Installing automated solids screw augers and sediment baskets to reduce manual pit cleaning frequency by up to 80%.
Automated Chemical Dosing & Foaming
Replacing manual detergent buckets with precision venturi or positive displacement chemical metering skids.
Telemetry & Cloud Diagnostic Enablement
Fitting cellular/Ethernet IoT gateways to enable remote run-hour logging, cycle counting, and predictive fault alarms.
The Upgrade Process.
From condition survey and obsolescence risk mapping through to phased delivery and commissioning.
Site Condition Survey
Comprehensive mechanical, electrical, and hydraulic inspection of existing plant assets.
Obsolescence & Risk Mapping
Identifying unsupported PLCs, obsolete pump parts, and critical failure points.
Feasibility & ROI Scoping
Modelling the capital cost of targeted upgrades versus full plant replacement.
Bespoke Upgrade Engineering
CAD design of skid interfaces, electrical wiring diagrams, and pipe reticulation.
Off-Site Skid Pre-Fabrication
Assembling and pre-testing pump, heating, and control skids to minimise site downtime.
Phased Site Installation
Executing mechanical and electrical cutovers during scheduled operational shutdowns.
Commissioning & New Baseline
Performance tuning, safety sign-off, and logging the upgraded plant into a new digital asset register.
Service to CAPEX. And CAPEX to Service.
01. Existing wash plant suffers recurring faults or high running costs
02. Alkota executes comprehensive Site Condition Survey
03. Engineer identifies specific obsolete or failing subsystems
04. Targeted Refurbishment / Upgrade proposal issued with ROI model
05. Phased site installation and commissioning
06. Plant re-baselined with new digital asset register & PPM contract
01. Turnkey design and engineering of new wash plant (£100k–£1m+)
02. Site commissioning and formal Site Acceptance Testing (SAT)
03. One-click conversion into Managed Asset in Alkota CRM
04. Scheduled PPM programme and critical spares consignment
05. Multi-year condition monitoring and obsolescence tracking
06. Scheduled life-extension upgrades at year 7–10
Request a Wash Plant Condition Survey.
Our application engineers inspect existing wash bays, identify obsolete controls or failing pumps, evaluate water recycling potential, and provide a structured refurbishment roadmap.
Preparing a capital project or formal tender?
We work directly with Engineering Directors, Operations Managers, M&E Consultants, and Principal Contractors. We provide hydraulic sizing calculations, process flow diagrams, trade effluent advice, and CAD interfaces.