Fueltek case study · Haulage & logistics
Fowler Welch
A coordinated ten-site migration from ageing equipment to modern Fueltek systems.
Fowler Welch needed ageing fuel management hardware updated across ten individual locations. Because the existing systems were still part of live operations, the changeover had to be coordinated carefully to keep downtime low.
Sector context image
Project approach
From operational problem to working system.
Fowler Welch’s migration required site-specific equipment choices and a coordinated changeover across ten live locations.
Modernise ten live sites without creating unnecessary downtime
- Each location had its own operational requirements and could not simply receive an identical hardware package.
- The existing fuel management network needed to remain usable while replacement equipment was introduced.
- The wider group wanted a modern platform that aligned with established Fueltek use elsewhere.
Plan the migration site by site
- Specified a mix of equipment appropriate to the individual locations.
- Introduced FT4000 fuel management hardware supported by TankWatch monitoring.
- Coordinated the changeover so systems could migrate with minimal disruption to fleet operations.
Project in context
The brief, explained in more detail.
The project brought together the equipment and operating processes described below. Explore how the installation worked and the considerations for a similar system at your site.
Modernisation across ten working locations.
Fowler Welch needed to modernise ageing fuel management equipment at ten individual locations. The existing systems were still part of daily fleet operations, so replacement involved more than selecting new hardware: the changeover had to keep the operating network usable.
Fueltek specified a mix of equipment to suit the individual sites, introducing FT4000 management supported by TankWatch monitoring. The programme did not assume that every location could receive an identical package. Local requirements shaped the equipment while the wider business moved towards a more consistent Fueltek-based platform.
The migration was coordinated to limit disruption, and Fueltek recorded the project as delivered on time and aligned with Fowler Welch’s operational requirements. The site-by-site approach allowed the replacement programme to reflect the operating requirements of the individual locations.
System architecture
How the Fueltek layers worked together.
A fuel-management project normally has several distinct jobs to do: physically store or dispense product, decide who is allowed to use it, measure what is held in storage, and turn activity into information that managers can review. The cards below show the roles of the systems connected with this case study.
FT4000
Authorised dispensing and transaction control
The FT4000 is the control layer at the fuelling point. It can be used to authorise dispensing, associate a transaction with an approved user or vehicle and create a structured transaction record instead of leaving the pump as an isolated piece of equipment. Where the project configuration captures additional fields such as mileage or identification data, those details can sit alongside the quantity dispensed so later reporting has operational context.
Explore FT4000 →TankWatch
Independent tank-level and stock monitoring
TankWatch measures what is physically held in the storage tank using tank probes and a local control layer. That gives the operator information such as current stock, available capacity, deliveries, stock movements and throughputs. It complements pump transaction data because it answers a different question: the pump records what the system says was dispensed, while tank monitoring measures what is actually happening in storage.
Explore TankWatch →FMO software
Browser-based reporting and multi-site visibility
Fueltek FMO provides the reporting and management layer above the field equipment. Depending on the installed configuration, authorised users can review fuel activity, run reports and manage information across users, vehicles, pumps or depots. On multi-site projects this is particularly important because it allows several physical locations to be viewed through one consistent reporting structure rather than as isolated fuel stations.
Explore FMO software →Operational workflow
From fuel on site to usable information.
The steps below explain the roles of the technologies discussed in this project. The exact operating sequence depends on the equipment and identification process specified for the installation.
Store & receive
Bulk product is received into the site storage arrangement. Tank capacity, product compatibility and delivery access are part of the physical specification before the management system can add useful control.
Authorise
The managed dispensing layer checks that the user or vehicle is permitted to draw fuel before the transaction proceeds. The exact identification method depends on the project configuration.
Dispense & record
Fuel is dispensed through the managed pump or controller. The quantity dispensed becomes a transaction record rather than remaining only as a mechanical pump total.
Measure stock independently
TankWatch measures the physical tank level. This gives the operator a second information source for stock, deliveries and movements alongside the pump transaction record.
Review & report
The reporting layer brings field data into a browser-accessible management view so authorised users can review activity without standing at the pump.
Planning a similar project
What should be defined before specification.
The case-study equipment should not be copied blindly. A new installation needs to be sized and configured around the actual operation. These are the main questions We need to understand before choosing the appropriate hardware and software.
Fuel & storage
Which products are stored? What is the expected daily usage, peak usage, delivery frequency and reserve requirement? These answers influence tank capacity and whether multiple compartments are appropriate.
Vehicles & dispensing
Vehicle type, fill-point position, desired flow rate, hose reach and simultaneous fuelling demand determine the practical pump, hose and nozzle arrangement.
Access & accountability
Define whether authorisation should be tied to a driver, vehicle, department, contractor or another operational identity, and what information needs to be captured with each transaction.
Tank visibility
Decide what the site needs to know about physical stock: current level, ullage, deliveries, movement, alarms and how that information should be reconciled with pump transactions.
Reporting & users
Identify who needs reports, whether the organisation is single-site or multi-site, which managers need local or central access and what exceptions should be easy to investigate.
Installation & handover
Existing equipment, electrical and data connections, vehicle movements, groundwork, commissioning windows, staff training and any fixed go-live date all affect the delivery plan.
Apply the learning
What to take into your own project.
For a similar migration, record the equipment and operating constraints at each location before fixing the rollout plan. Keep shared reporting requirements separate from the local installation decisions that may need to vary.
Read the project outcome →Case-study FAQ
Project detail and specification questions.
These answers separate the recorded facts of this case study from the decisions that would need to be made for a new installation.
What was the main issue this haulage & logistics project needed to solve?
Modernise ten live sites without creating unnecessary downtime. Each location had its own operational requirements and could not simply receive an identical hardware package. The existing fuel management network needed to remain usable while replacement equipment was introduced.
Which Fueltek systems are connected with this case study?
This project brought together FT4000, TankWatch and FMO software. Each system has a distinct role in fuel control, storage, monitoring or reporting.
Why use both pump records and tank monitoring where both are installed?
They measure different parts of the operation. Managed dispensing records the authorised transaction at the pump, while tank monitoring measures physical stock and movements in storage. Reviewing both gives the operator more context than either source on its own.
Would a new project use exactly the same specification?
Not automatically. A similar project should be specified around fuel type, storage capacity, peak dispensing demand, hose reach, user and vehicle access, communications, reporting requirements, installation constraints and any existing equipment that is suitable to retain.
What should be defined before a site survey or quotation?
Useful starting information includes the products to be stored, approximate daily and peak usage, current tank and pump details, vehicle types, required flow rate, number of users or vehicles, preferred access method, reporting expectations, communications available at the site and any installation or handover deadline.
Project outcome
What changed.
The rollout updated the ageing estate while keeping the operating network available and giving the group a more consistent Fueltek-based platform.
Relevant Fueltek systems
Explore the technology used.
Equipment is specified around the site, fuels, users, reporting requirements and existing infrastructure. The links below show the closest current Fueltek product areas connected with this project.
Plan your own system
Have a similar operational challenge?
Fueltek can review your tanks, pumps, vehicles, users, reporting requirements and existing equipment before recommending the most practical route forward.
