Extend the life
of the plant.
A £500k+ wash installation should not be scrapped simply because one subsystem is obsolete. Alkota brownfield engineering delivers targeted refurbishment, automation upgrades, and water treatment retrofits on live operational sites.
Phased Delivery on Live Operational Sites.
We understand that halting operations for weeks is commercially unviable. Our engineers execute phased brownfield overhauls — preparing skids off-site and scheduling cutovers during planned downtime windows.
Common Plant Modernizations.
Pump Skid Modernization
Replacing obsolete, undersized, or worn pump units with modern high-efficiency triplex ceramic plunger assemblies with soft-start VSD control.
PLC & Automation Migration
Upgrading hard-wired relay panels or obsolete PLCs to modern Siemens / Mitsubishi architectures with touchscreen HMI and telemetry.
Water Recycling Retrofit
Adding closed-loop media sand filtration and coalescing oil separation to convert direct-discharge wash bays into sustainable, compliant facilities.
High-Efficiency Thermal Coils
Replacing scaled or inefficient heating coils with continuous Schedule 80 ASTM A53 assemblies and high-efficiency gas/diesel burners.
Automated Underbody Rigs
Adding automated chassis and wheel wash spinner bars to existing manual wash bays to accelerate vehicle turnaround times.
Safety & Interlock Compliance
Retrofitting Category 4 dual-channel E-stop loops, light curtains, and safety isolation valves to meet current UK EHS standards.
The CAPEX & Service Continuity Loop.
Alkota manages the full lifecycle: from legacy plant audits through upgrade engineering, handover, and ongoing planned maintenance.
01. Existing plant experiences repeated breakdown
02. Alkota performs comprehensive condition report
03. Targeted engineering upgrade replaces obsolete sub-systems
04. Refurbished plant handed over into structured PPM agreement
01. Turnkey new wash plant designed and commissioned
02. Asset register created in client portal
03. Multi-year scheduled PPM & telemetry monitoring
04. Planned component replacement roadmap prevents obsolescence