We were asked to design and build a fully mobile pressure washer system for a driveway cleaning contractor based in Birmingham. Having worked with this customer previously, his business had expanded following a new contract, and his cleaning requirements had changed significantly.

He supplied two diesel pressure washers and asked us to fabricate a secure, van-mountable system that would allow him to operate independently of mains water and electricity.

Problem / Requirement

• Existing setup: Two diesel pressure washers mounted on trolley frames.
• Main issue: Machines were not optimised for van installation and off-grid operation.
• Operational challenge: Required a fully self-contained system for working in areas with no water or power supply.
• Business growth: Increased workload meant efficiency, reliability, and professional setup were now essential.

The contractor needed a secure, compact, and practical solution that could be mounted inside his van and used anywhere.

Our Solution

• Removed both diesel pressure washers from their original trolley frames.
• Fabricated and installed a custom mounting frame suitable for secure van installation.
• Mounted both machines directly to the frame to create a stable, integrated system.
• Connected the machines to the van’s main water tank for fully independent operation.
• Installed anti-vibration mounts to reduce stress and movement on the frame during transport and operation.
• Fitted two hose reels to keep hoses organised, protected, and easy to deploy.
• Ensured the system could be mounted and removed efficiently when required

The Result

• The contractor now has a fully self-contained, off-grid pressure washing system.
• Both diesel machines are securely mounted and integrated into the van.
• Anti-vibration mounting improves durability and reduces long-term wear.
• Dual hose reels keep the setup neat, professional, and quick to use.
• The system allows him to work anywhere, even where no water or electricity is available.
• His upgraded setup supports his new contract requirements and business growth.

We were called out to replace a damaged water tank on a Nilfisk Delta Booster system. The original tank had deteriorated and was no longer suitable for reliable operation, so we arranged for a custom stainless steel replacement tank to be manufactured and installed.

Problem / Requirement

• The existing Delta Booster multi-pump tank had deteriorated and required replacement.
• The tank feeds multiple pumps, so reliability and durability were essential.
• The original setup also required new hoses to properly connect the replacement tank to the pump system.
• The customer wanted a long-term solution that would resist corrosion and wear.

Our Solution

• Arranged for a custom stainless steel tank to be manufactured specifically for the Nilfisk Delta Booster system.
• Removed the original tank and prepared the system for the new installation.
• Installed the new stainless steel multi-pump tank in place of the old unit.
• Fitted new hoses and connections to correctly supply water to each pump.
• Checked all connections and ensured the system was correctly supplied with water.

The Result

• The Delta Booster system now has a durable stainless steel tank that will resist corrosion and wear.
• New hoses ensure reliable water supply to each pump.
• The upgrade provides a long-term, robust solution for the multi-pump wash system.
• The machine is now back in operation and ready for continued heavy use.

We were called out to repair a Nilfisk Delta Booster multi-pump system at an abattoir in Telford. The system had begun experiencing issues due to corrosion on the capillary pipes connected to the pressure manifold.

Problem / Requirement

• Machine type: Nilfisk Delta Booster multi-pump system.
• Issue: Several capillary pipes on the pressure manifold had become heavily corroded.
• Risk: The corrosion was causing weakening of the pipes and potential leaks within the pressure monitoring system.
• Environment: The machine operates from a plant room in an abattoir 

If left unattended, the damaged pipes could lead to pressure control faults or leaks within the system.

Our Solution 

• Removed the corroded capillary pipes from the manifold assembly.
• Fabricated, bent into shape, and installed new replacement capillary pipes.
• Ensured all fittings were correctly sealed and secured.
• Checked the manifold system for leaks and confirmed correct operation.

The Result

• The Delta Booster system is now operating reliably again with new corrosion-free capillary pipes installed.
• The pressure monitoring system is working correctly with no leaks present.
• Replacing the damaged pipework has improved the reliability of the system in a demanding washdown environment

We were asked to install a new static hot Nilfisk SH Truck stainless steel pressure washer system for a farm in Twycross that sells and maintains ATV bikes. The customer needed a reliable hot water machine for regular equipment cleaning but struggled with low water pressure and wanted the unit kept indoors with simple external operation.

Problem / Requirement

• Existing machine: An older Ehrle HSC unit was already on site and required frequent repairs.
• Main issues: Low mains water pressure, inefficient workflow, and the need to operate outdoors without accessing the plant room.
• Site conditions: All cleaning is carried out outside, and the system needed to avoid freezing and dirt exposure.
• Usage: Approximately 10 hours per week for ATV and farm equipment cleaning.

We had been repairing the Ehrle machine for the customer for years, but ongoing repair costs and performance limitations made a new installation the best long-term solution.

Our Solution / Work Carried Out

• Supplied and installed a Nilfisk SH Truck static hot stainless pressure washer as the primary washdown system.
• Installed a 200L water barrel to guarantee a consistent feed despite low mains pressure.
• Fitted a boost pump between the barrel and machine to deliver a smooth, steady flow to the high-pressure pump.
• Installed a chimney flue through the wall to safely vent boiler exhaust outside.
• Drilled through the wall and fitted an external hose point and retractable hose system for outdoor cleaning without moving the machine.
• Installed external remote start/stop controls so the operator can run the machine from outside the building.
• Repaired and retained the existing Ehrle HSC as a backup machine for the farm.

The Result

• The Nilfisk SH Truck now provides reliable hot water cleaning, making ATV washdowns quicker and more efficient.
• The 200L tank and boost pump ensure smooth, consistent pressure even with low mains supply.
• External controls and hose access allow operators to wash equipment outdoors without entering the building, saving time, reducing freezing risks, and keeping the plant room clean and secure.
• The customer has reduced ongoing repair costs while still keeping the old machine as a backup.

We were asked to design and install a completely custom pressure washer system for a professional vehicle detailer in Coalville. The customer wanted a compact, wall-mounted setup that would fit neatly into the corner of his workshop, provide spotless rinsing for finished vehicles, and make daily washing quicker and easier.

Problem / Requirement

• Existing setup: The detailer was using a cheap portable pressure washer from the side of his mobile van and did not have a dedicated setup in his workshop.
• Main issues: No access to ionised or purified water, water spotting and streaks on final rinses, limited pressure and performance, and slow workflow due to constantly moving equipment.
• Site conditions: Limited workshop space, corner installation required, and daily washdowns on detailed vehicles.
• Usage: Regular weekly use for professional valeting and detailing work.

The customer wanted a permanent, professional system that was fixed in place, out of the way, and designed to improve finish quality and workflow inside the workshop.

Our Solution / Work Carried Out

• Built and installed a fully custom wall-mounted pressure washer system designed to fit perfectly into the corner of the workshop.
• Fitted a TDS (Total Dissolved Solids) meter to enable the use of ionised water for spot-free, streak-free final rinses.
• Integrated ionised water capability to improve finish quality on detailed vehicles.
• Installed a 20-metre hose reel beneath the pump hardware with lightweight hose to make vehicle washing easier and reduce drag across the floor.
• Added a nozzle holder on the side of the machine to allow quick changes of spray angle for different cleaning tasks.
• Mounted the system securely to the wall to keep the unit off the floor, maximise workspace, and protect the equipment.

The Result

• The custom wall-mounted system delivers compact, efficient operation while freeing up valuable floor space in the workshop.
• The TDS meter and ionised water capability allow for spot-free, streak-free rinsing, improving the finish on detailed vehicles.
• The 20-metre lightweight hose and reel make washing easier, faster, and more ergonomic during daily use.
• The nozzle holder enables quick spray-angle changes, making the cleaning process more versatile and convenient.
• The customer now has a clean, professional setup that’s permanently fixed, out of the way, and tailored specifically to his workflow.

We were asked to supply and install a reliable cold static pressure washer system for an emergency services site in Leicester. The machine is used for regular ambulance washing, helping keep the fleet clean and presentable.

Problem / Requirement

• Existing setup: The site required a dedicated, fixed pressure washer for vehicle cleaning.
• Main issues: No permanent washdown system in place and a need for fast, efficient cleaning to minimise vehicle downtime.
• Site conditions: Ambulances require frequent cleaning, with quick turnaround times and minimal setup.
• Usage: Regular daily washing of emergency service vehicles.

The customer needed a dependable, easy-to-use system that would allow staff to wash vehicles quickly without moving having to move equipment or fight tangled hoses.

Our Solution / Work Carried Out

• Supplied and installed a Nilfisk DTE cold static pressure washer as a fixed vehicle washdown solution.
• Built and installed a custom stainless steel mounting frame to securely house the machine and protect it in a busy working environment.
• Installed an automatic retractable hose reel beneath the unit to keep the wash area tidy and make hose handling quick and effortless.
• Modified the system to ensure smooth hose operation and easy access during vehicle washing.
• Mounted the system at an ergonomic height to allow fast connection and efficient use when washing ambulances.
• Fully commissioned the machine and ensured the system was ready for immediate use.

The Result

• The Nilfisk DTE system now provides a reliable, fixed washdown solution for ambulance cleaning.
• Ambulances can be washed quickly and efficiently, reducing downtime and improving fleet presentation.
• The automatic retractable reel keeps the area clear of trailing hoses, improving safety and organisation.
• The custom stainless steel frame provides durability, protection, and a clean professional finish.
• Staff can now simply pull the hose, wash the vehicle, and retract the reel—making daily cleaning faster and easier.

We were asked to supply, install, and fully customise a Nilfisk 400HS DTE pressure washer system for a FedEx site, used for cleaning lorries on a daily basis. The customer needed a reliable, user-proof setup that could handle multiple operators while preventing misuse, damage, and unnecessary downtime.

Problem / Requirement

• Existing setup: Standard machine configuration not suited to a busy lorry washdown environment.
• Main issues: Risk of unauthorised use, inconsistent water supply, and potential fuel-related burner issues.
• Site conditions: High-traffic depot with multiple users and frequent, heavy-duty cleaning of vehicles.
• Usage: Daily lorry washdown requiring consistent performance, reliability, and ease of use. 

The system needed to be robust, simple to operate, and protected against the common causes of failure in high-use environments.

Our Solution

• Supplied and installed a Nilfisk 400HS DTE pressure washer system.
• Fitted keypad access (PIN or fob) – ensures only authorised users can operate the machine, reducing misuse, preventing accidental damage, and improving accountability.
• Modified the flue system – prevents rainwater entering the boiler, reducing corrosion, avoiding burner lockouts, and extending boiler life.
• Installed a Tiger Loop system – removes air from the fuel line and stabilises fuel delivery, resulting in a cleaner burn, fewer flame failures, and more reliable operation.
• Upgraded fuel system with new tank and low fuel cut-out – automatically shuts the machine down if fuel runs low, preventing dry running, sooting, and costly burner damage.
• Installed low water cut-out – protects the pump by shutting the system down if water supply drops, eliminating the risk of running dry and damaging internal components.
• Set up low-pressure and high-pressure chemical systems – gives flexibility for different cleaning stages, from pre-soaking and foaming to deeper, more aggressive cleaning when needed.
• Added a pressure accumulator – smooths out pressure spikes, improving user experience while reducing stress and wear on the pump.
• Installed rear-mounted hose reel – keeps hoses organised and off the ground, reducing trip hazards, preventing damage, and improving overall site tidiness.
• Fitted a boost pump – ensures consistent inlet pressure regardless of site supply fluctuations, improving performance and significantly increasing the lifespan of the main pump.

The Result

• A fully customised lorry wash down system built specifically for a busy FedEx depot.
• Controlled access reduces misuse and extends the life of the machine.
• Improved burner reliability with a stable, clean fuel system.
• Full protection against low water and low fuel conditions, preventing breakdowns.
• Smoother, more consistent performance for all users.
• Safer, cleaner working environment with better hose management.
• A long-term solution designed to minimise maintenance, reduce downtime, and maximise reliability.

Modifications carried out on a Nilfisk SH Truck for a haulage company in Shepshed to improve reliability and resolve ongoing fuel and water supply issues.

The machine is used regularly for cleaning HGVs and trailers, so a consistent, self-contained setup was required to minimise downtime and improve day-to-day operation.

Problem / Requirement

• Machine drawing fuel from a bunded IBC tank located behind the workshop
• Ongoing fuel supply issues causing inconsistent burner performance
• Air entering the fuel line leading to flame failures and lockouts
• No fuel level protection, with risk of running the tank dry
• Inconsistent water supply creating risk of inlet starvation
• Requirement for a more reliable, simplified setup suitable for regular use

Our Solution

• Installed inlet water tank to provide a constant buffer of water to the machine stopping inlet starvation and cavitation. The tank ensures consistent flow to the pump, improving reliability and pump lifespan
• Installed new dedicated fuel tank, removing original reliance on external IBC fuel supply, eliminating issues caused by long fuel lines and inconsistent fuel draw. Reduces risk of air ingress and contamination and improves burner performance and combustion stability
• Installed fuel level switch (low fuel cut-out) that automatically shuts the machine down when fuel level is too low; prevents the burner running dry

The Result

A significantly more reliable and user-friendly setup tailored to the demands of a busy haulage environment.

The system now benefits from a consistent water supply, a stable and controlled fuel source, and built-in protection against common failure points.

This upgrade removes previous fuel-related issues and protects the machine from avoidable damage, ensuring it can operate reliably under regular daily use.

We were asked to upgrade an existing Nilfisk multi-pump system at a food factory in Birmingham that was struggling to keep up with demand during nightly clean-downs.

With multiple pumps running simultaneously, the system required increased water capacity and improved control to ensure consistent performance and prevent interruptions.

Problem / Requirement

• Existing setup: Multi-pump system with an 80 litre water tank.
• Main issues: System running out of water when all pumps were in use, causing pressure drops and inconsistent performance.
• Site conditions: High-demand environment with all pumps operating during nightly clean-downs.
• Usage: Intensive, regular cleaning requiring consistent flow and reliability across all pumps.

The goal was to increase system capacity and improve control so the setup could handle full demand without running dry or affecting performance.

Our Solution

• Upgraded the system with a larger 160 litre water tank to increase available capacity.
• Installed new level switches to maintain correct water levels and prevent both overflow and dry running.
• Fitted new solenoids to improve control of water entering the tank and ensure reliable refill operation.
• Installed a new thermostat to maintain stable operating conditions and protect system components.
• Replaced feed hoses to all pumps to improve flow and ensure even water distribution across the system.

The Result

• System now capable of handling full demand with all pumps running simultaneously.
• Eliminated water shortages during nightly clean-down operations.
• The site has since upgraded from a 5 pump system to a 6 pump system, and has not run out of water during clean-down since the tank upgrade.
• Improved consistency in pressure and overall performance.
• Reduced risk of pump damage caused by poor inlet conditions.
• More reliable and controlled system suited to a high-demand industrial environment.
• Long-term performance improved through increased capacity and upgraded components.

We were asked to modify an existing Nilfisk DTE static pressure washer at a brewery in Burton. The machine is used for high-temperature cleaning of beer kegs, operating in a confined courtyard area where exhaust fumes from the boiler were becoming an issue.

Problem / Requirement

• Existing setup: Nilfisk DTE static machine installed in a small enclosed courtyard.
• Site conditions: Restricted space with limited airflow, increasing the impact of fumes.
• Usage: High-temperature cleaning of beer kegs, meaning the burner is regularly in use for extended periods.
• Main issues: Boiler exhaust fumes and smoke building up in the wash area during operation.

The customer needed a solution to safely manage and redirect exhaust fumes away from the working area, improving both operator comfort and overall safety.

Our Solution

• Assessed the existing flue setup and site layout to determine the most effective route for exhaust redirection.
• Supplied and installed a stainless steel flue extension system.
• Extended the flue vertically to safely carry exhaust gases above roof height.
• Secured and supported the flue to ensure long-term durability and stability in an outdoor environment.
• Ensured correct routing to maintain proper burner performance and airflow.

The Result

• Exhaust fumes are now safely redirected away from the courtyard wash area.
• Improved working conditions for operators with significantly reduced smoke exposure.
• Maintained efficient burner performance while resolving the fume issue.
• A simple but effective modification tailored to the site layout and usage requirements.
• Long-term, low-maintenance solution using durable stainless steel components.

We were called back to a food processing factory in Mansfield where we had previously carried out a number of modifications to their cold pressure washer systems. These machines are fed with hot water to assist with heavy-duty factory clean downs, meaning the setup needs to handle both high usage and elevated temperatures reliably.

Problem / Requirement

• Existing setup: Previously modified cold pressure washer systems with plastic inlet tanks.
• Main issues: Tanks deforming due to hot water supply, lack of sealing causing condensation, and internal cabinet contamination.
• Site conditions: Food production environment requiring high hygiene standards and consistent daily washdown performance.
• Usage: Regular clean downs using hot water feed to improve cleaning efficiency.

The original plastic tanks were not suitable for prolonged exposure to hot water. They began to warp over time, and because they were not sealed, condensation built up inside the cabinets, leading to wet, dirty internal conditions and increased risk of component failure. 

Our Solution

• Removed the existing plastic inlet water tanks that had deformed under heat.
• Supplied and installed new stainless steel tanks, purpose-built to handle hot water applications.
• Fitted sealed lids to eliminate condensation and protect internal components.
• Retained and integrated previous system upgrades, including:
• Boost pumps for consistent inlet pressure.
• New hoses and upgraded pipework.
• Replacement unloaders for improved pressure control.
• Previously installed level switches for system protection.
• Ensured all modifications worked together as a complete, reliable system.

The Result

• A far more durable and heat-resistant water storage solution suited to hot feed applications.
• Elimination of tank deformation issues.
• Significant reduction in condensation inside the cabinet, improving cleanliness and reliability.
• Protection of internal components from moisture-related damage.
• Improved hygiene standards within the system, better suited to a food production environment.
• A long-term, reliable setup built to handle daily high-demand cleaning without recurring issues.

We were called out to a farm in Enderby where a Nilfisk SH Truck Booster system was repeatedly being brought back for repair due to ongoing issues with leaks and overheating. The machine required a preventative solution rather than repeated reactive repairs.

Problem / Requirement

• Existing setup: Nilfisk SH Truck Booster in regular farm use.
• Main issues: Leaking trigger guns causing the machine to run continuously, leading to overheating and component damage.
• Additional faults: Sticking ball valve causing the inlet tank to overflow.
• Site conditions: Unattended operation at times, increasing the risk of prolonged running.
• Usage: Frequent agricultural cleaning with risk of operator oversight.

The machine had previously been left running overnight due to leaking guns, which caused the pump to overheat, warp the tank, and ultimately melt the internal pump seals. This resulted in repeated breakdowns and ongoing repair costs. A solution was needed to both repair the damage and prevent it from happening again.

Our Solution

• Replaced damaged pump seals caused by overheating.
• Installed an over-temperature protection system to monitor pump head temperature.
• Configured the system to automatically shut the machine down if the pump exceeds 60°C.
• Integrated this with the machine’s programmed shutdown timer to provide an additional layer of protection.
• Replaced the faulty ball valve that was sticking and causing tank overflow.
• Carried out a full clean-down of the machine and internal components.
• Ensured all systems were operating correctly and safely following modification.

The Result

• Fully repaired system with new seals and restored pump performance.
• Automatic protection against overheating, preventing damage from unattended running.
• Dual-layer protection with temperature cut-out and programmed shutdown timer.
• Elimination of overflow issues with a properly functioning inlet valve.
• Reduced risk of costly breakdowns and repeat call-outs.
• A far more user-proof system designed to handle real-world farm conditions.
• Long-term reliability improved through preventative design rather than repeated repair.

This was a good example of putting a proper solution in place to stop the issue happening again, rather than just repairing the same fault repeatedly.

We were asked to design and build a dedicated wheel wash system for a hatchery in Rugby. The system needed to be installed externally and provide a reliable, controlled cleaning process to maintain strict site hygiene standards for incoming vehicles.

Problem / Requirement

• Existing setup: No dedicated wheel wash system in place for controlled vehicle entry.
• Main issues: Risk of contamination entering the site, inconsistent cleaning methods, and no structured wash process.
• Site conditions: Outdoor installation exposed to the elements, requiring a robust and weather-resistant solution.
• Usage: Frequent vehicle access requiring a consistent and repeatable cleaning process using multiple detergents.

The customer required a fully self-contained system capable of delivering a structured multi-stage wash process, while being durable enough for outdoor use.

Our Solution

• Supplied and installed a DTE stainless steel cabinet suitable for outdoor use.
• Built the system around a CAT pump for reliability and consistent performance.
• Installed a Kothar triple outlet turn and clean system to allow a 3-stage detergent application process.
• Configured the system to handle multiple detergents for a structured wash procedure.
• Integrated an internal hose reel for a clean and organised working setup.
• Fitted an internal water inlet tank to ensure consistent water supply and protect the pump.
• Designed the system as a fully self-contained unit for ease of use and minimal operator error.

The Result 

• A fully bespoke wheel wash system tailored to strict hygiene requirements.
• Consistent and repeatable 3-stage cleaning process for all incoming vehicles.
• Reliable performance thanks to high-quality components and controlled water supply.
• Durable, weather-resistant setup designed specifically for outdoor installation.
• Cleaner, more organised system layout with improved usability for operators.
• Reduced risk of contamination entering the site through proper wash procedures.

This installation delivered a purpose-built solution that goes beyond a standard pressure washer, providing a controlled and reliable cleaning process suited to the demands of a biosecure environment.

We were asked to replace an ageing Nilfisk Neptune 7 setup for a fleet cleaning company in Tamworth. The customer wanted to repurpose their existing mobile machine into a van setup, meaning a new static system was required to handle the daily cleaning workload reliably.

Problem / Requirement

• Existing setup: Older Nilfisk Neptune 7 machine previously used as the site’s main cleaning system.
• Main issues: Boiler scaling issues, ageing components, and the need to free up the mobile machine for van use.
• Site conditions: High-use fleet cleaning environment requiring reliable hot water performance and consistent chemical application.
• Usage: Regular vehicle and fleet washing with varying cleaning requirements depending on contamination levels.

The customer required a more permanent and reliable static installation that would improve long-term reliability while also giving greater flexibility with chemical application and system protection.

Our Solution

• Supplied and installed a brand new Nilfisk SH Truck static pressure washer system.
• Removed and replaced the old Neptune 7 installation.
• Installed a new stainless flue system for safe boiler exhaust management.
• Fitted low-level cut-outs for water, chemical, and fuel to protect the machine from running dry.
• Installed both low-pressure and high-pressure chemical injection systems for improved cleaning flexibility.
• Fitted a water softener system to reduce scale build-up and protect the boiler and internal components.
• Modified the inlet water tank and installed a new float valve system for improved water regulation and reliability.
• Reconfigured the site setup to allow the original Neptune 7 to be repurposed into a mobile van cleaning unit.

The Result

• A modern static hot wash system built specifically for daily fleet cleaning use.
• Improved system protection through integrated low-level safety cut-outs
• Reduced risk of boiler scaling and improved long-term reliability thanks to the water softener installation.
• Greater flexibility in cleaning performance with both high and low-pressure chemical application.
• More reliable water control through the upgraded tank and float valve setup.
• Allowed the customer to continue using their Neptune 7 as a separate mobile cleaning solution without compromising the site setup.

This installation not only upgraded the customer’s main cleaning system, but also improved the overall efficiency and flexibility of their operation moving forward.

This customer wanted a more effective way of applying chemicals through their Nilfisk Truck Booster for regular farm cleaning duties in Ellistown. The existing setup offered limited detergent application, so we modified the machine with a dedicated chemical injector system to improve cleaning performance and usability. 

Problem / Requirement

• Existing setup: Nilfisk Truck Booster with limited chemical application capability.
• Main issues: Poor detergent application and lack of flexibility when carrying out heavy agricultural cleaning work.
• Site conditions: Farm environment with regular machinery, vehicle, and equipment wash down requirements.
• Usage: Frequent cleaning of agricultural equipment requiring effective pre-soak and detergent coverage.

The customer required a simple and reliable chemical application system that could improve cleaning performance without overcomplicating the machine setup.

Our Solution

• Installed a dedicated external chemical injector onto the side of the Nilfisk Truck Booster.
• Modified pipework and fittings to integrate the injector into the existing wash system.
• Configured the system for improved detergent draw and application performance.
• Tested chemical injection operation and overall machine performance.
• Ensured the modification remained accessible and easy to maintain for future servicing work.

The Result

• Improved chemical application and detergent coverage for daily farm cleaning tasks.
• More effective pre-soaking and cleaning performance on heavily contaminated equipment.
• Simple and reliable modification without affecting the machine’s normal operation.
• Easier day-to-day use for the customer with improved overall cleaning flexibility.

This customer uses their Nilfisk Neptune 7 extremely heavily, with the machine regularly operating for up to 16 hours a day under constant trigger on/off use. Due to the demanding workload, the original unloader valve assembly was wearing too often, causing repeated reliability issues and unnecessary downtime.

Problem / Requirement

• Existing setup: Nilfisk Neptune 7 hot pressure washer used for intensive daily cleaning work.
• Main issues: Premature unloader valve wear caused by constant trigger cycling and prolonged daily operation.
• Site conditions: Very high machine usage with heavy demand placed on the pump and pressure regulation system.
• Usage: Daily washdown work with repeated stop/start trigger operation over long periods of time.

Although the original Nilfisk Alto unloaders are generally very reliable, this particular application was simply too demanding for the standard setup long-term.

Our Solution

• Converted the machine from the original Nilfisk Alto unloader setup to a VB9-style unloader system.
• Modified fittings and pressure regulation setup to suit the new unloader configuration.
• Fully stripped the pump assembly for inspection and wear checks.
• Serviced the pump including seals, valves, and general inspection work.
• Carried out a full burner service to maintain reliable heating performance.
• Tested machine operation, pressure regulation, and bypass function following modification.

The Result

• Significantly improved long-term reliability under heavy daily use.
• Reduced unloader wear despite constant trigger cycling throughout the day.
• Improved machine uptime and reduced maintenance frequency for the customer.
• Fully serviced and inspected machine ready for continued heavy-duty operation.
• Since converting the machine to the VB9-style setup, the customer has not experienced further unloader wear issues.