Automation has been part of commercial vehicle wash systems for many years, but its role is often misunderstood. In practice, automation in a modern lorry wash is not about removing people entirely from the process or introducing experimental computer technology. Instead, automation aims to improve consistency, reliability, and control in high throughput fleet depots.
In this article, we look at five of the automation technologies that are widely used today in commercial vehicle washing, explaining why they matter.
Commercial vehicle washing (e.g. trains, buses, lorries, fleet vans etc) presents challenges that differ significantly from passenger car washing. Vehicles vary in height, length, and equipment, wash cycles are more frequent, and systems must operate reliably in wet, abrasive conditions. For this reason, automation in commercial vehicle wash systems has evolved in a pragmatic way. Technologies are generally adopted only where they demonstrably improve wash quality, reduce operator dependency, or protect equipment and vehicles over the long term. So, why do these five technologies lead the pack among the many automated systems available to modern operators?
At the centre of most automated commercial wash installations is a programmable control system, usually based on industrial PLC technology. These systems coordinate the entire wash sequence, controlling the interaction between mechanical components, water delivery, and chemical application.
This allows a lorry wash programme to be defined in advance and repeated consistently. For example, brush movement speed, dwell times, and rinse cycles can all be adjusted to suit different vehicle types or levels of soiling. Once configured, the system ensures that these parameters are applied in the same way for every wash, reducing your reliance on operator judgement.
Automation in a lorry wash or other commercial facility must account for wide variation in vehicle size and positioning. To manage this, modern systems use industrial sensing technologies to detect vehicle presence and profile. For instance, height and contour detection allows brushes and spray equipment to adjust automatically as the vehicle passes through the wash. This reduces the risk of missed areas or excessive contact pressure, particularly on roof-mounted equipment, mirrors, and signage. These systems are designed for reliability rather than precision optics, functioning consistently in low visibility conditions where dirt, spray, and debris could compromise more delicate technologies.
Brush automation is one of the most established elements of commercial vehicle washing. In a typical lorry wash, automated gantries move brushes around a stationary vehicle in a controlled and repeatable pattern.
The lorry wash brush itself is adjusted continuously throughout the wash cycle. Movement speed, contact pressure, and positioning are managed by the control system to suit the detected vehicle profile. This allows brushes to follow vehicle contours more accurately than manual washing, while
maintaining consistent cleaning performance across large fleets. Over time, this controlled operation reduces wear on both the brush materials and the vehicles being washed, contributing to lower maintenance requirements and a longer equipment life.
Chemical application is another area where automation provides tangible benefits in commercial vehicle wash systems. Automated dosing ensures detergents are mixed at consistent concentrations and applied at the appropriate stages of the wash. This improves cleaning performance and avoids the variability that can occur with manual mixing or application. Accurate dosing also helps mitigate your operating costs and reduces unnecessary chemical discharge, which is important for urban sites operating under environmental or drainage constraints.
Many commercial vehicle wash systems now incorporate water recycling systems, particularly where wash volumes are high. Automation plays a key role in making these systems reliable. Filtration, sludge removal, and backwashing processes are typically controlled automatically, allowing recycled water to be reused without constant operator intervention. This gives you stable system performance while reducing your fresh water demand, and supporting compliance with environmental requirements.
While automation in commercial vehicle washing is well established and adoption is growing, some technologies are often discussed but are not yet common in real-world operations. These technologies do exist in trials and niche applications, but are not yet feasible or cost-effective for most commercial vehicle wash systems.
û AI camera systems that analyse dirt levels in real time
û Fully autonomous wash sites with no human oversight
û Self-learning wash programmes that adapt without manual configuration
û Robotic arms replacing gantry-based wash systems at scale
If you are reviewing your use of automation within a commercial vehicle wash system, Britannia Wash Systems can provide practical guidance based on real-world installations. Please [click here] to find out more.
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