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Keypad + Multiple Other Modifications For A Stainless Nilfisk DTE 400HS In Leicester

What they needed

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.