Mechanical Maintenance for Biogas Plants: Services and Best Practices
Why Mechanical Maintenance Matters
In an anaerobic digestion plant, mechanical systems do the heavy lifting. Mixers keep feedstocks moving, pumps transfer slurries, screw conveyors handle solids, and hydraulic units power feed systems. When any one of these components falters, throughput drops and biogas yield suffers. Proactive maintenance is therefore not a luxury, it is a control measure for safety, compliance and performance.
Poor lubrication, worn seals and fatigued bearings are common culprits behind leaks and unplanned stoppages. A leaking mixer seal risks biogas escape and digestate loss, a failing progressive cavity pump can interrupt feed and upset biology, a blocked screw conveyor can halt solids handling entirely. Scheduled inspections, condition monitoring and timely part replacement keep risks low and output steady.
If the worst happens, rapid mobilisation is vital. Our Critical Response teams support sites when pumps, agitators or conveyors fail, helping you contain risk and return to production quickly.
BioContractors’ Mechanical Services
BioContractors delivers end to end mechanical maintenance for AD facilities across the UK and Ireland. Our engineers pair hands on experience with process insight so fixes do more than replace parts, they restore performance.
Mixers and agitators
Installation, alignment and refurbishment of seals, bearings and shafts. We optimise mixer angles and duty cycles to suit your tank geometry and feedstock profile.Pumps
Repair and overhaul for centrifugal and progressive cavity units, with seal and stator replacement, pressure testing and performance checks to stabilise feed and recirculation.Screw conveyors and solids handling
Clearance of blockages, flight repairs and wear part replacement. We tune speeds and loading to cut jamming and protect motors and gearboxes.Hydraulic power units and feed systems
Filter changes, hose replacement and flow optimisation so rams and feed screws run reliably under variable loads.Gas handling and safety systems
Compressor servicing, flare inspections and desulphurisation unit maintenance to keep gas quality stable and safety systems ready.Gas storage and conditioning
Membrane, bag and filter servicing to prevent leaks and maintain consistent pressure and purity.Pipework modifications and performance tuning
Fabrication and valve changes for new feedstocks or higher throughput, with pressure and integrity testing on completion. See our case work on mechanical fabrication for solid feeders.SCADA monitoring and optimisation
Alarm rationalisation, data analysis and dashboarding to turn raw signals into actionable maintenance decisions.Live interventions that avoid downtime
Where appropriate, we complete upgrades alongside targeted, non invasive works, including Live Core Drilling for sampling or equipment installation while tanks remain in operation.
You can explore related field work in our pressure release valve servicing case study.
Best Practices and Benefits
Effective mechanical maintenance is about prevention rather than cure. Regular inspections aligned with manufacturer guidance and EA permit requirements help identify issues before they escalate. Monitoring key data such as temperature, pressure and vibration trends provides early warning signs of wear or inefficiency. Consistent lubrication and seal management protect against leaks and unnecessary damage, while accurate record‑keeping lays the foundation for predictive maintenance.
The benefits are clear. Plants that embrace proactive maintenance see less unplanned downtime, improved energy output, and extended equipment lifespans. By keeping seals, mixers and pumps in top condition, operators also reduce safety risks and avoid unexpected costs linked to repairs or replacements
The Benefits You Can Measure
Investing in preventative maintenance returns value in ways finance teams recognise and operators feel on the ground.
Reduced downtime: issues are found early and fixed on planned windows, not during breakdowns.
Enhanced safety: sound seals and bearings cut the risk of gas escape and ignition; clear procedures reduce manual interventions.
Improved efficiency: tuned mixers and pumps draw less power for the same duty, while stable feed keeps biology in its sweet spot.
Extended asset life: regular servicing delays expensive replacements and de risks capital planning.
Mechanical Maintenance in the Industry
Across the sector, operators blend in house capability with specialist partners like BioContractors. Maintenance schedules are aligned with OEM guidance, EA permit requirements and HSE best practice. More plants are adopting predictive maintenance, placing sensors on mixers and pumps to flag bearing wear, misalignment and cavitation before they become failures. SCADA data, when cleaned and contextualised, supports decisions that protect uptime and compliance.
Where investigation is needed, non invasive techniques such as Live Core Drilling allow sampling or equipment installation without depressurising or emptying tanks, protecting biology and production.
How BioContractors Supports Your Plant
From emergency repairs to long term service agreements, BioContractors keeps AD facilities running at peak performance. We plan works around your feed schedule, bring the parts that fix root causes, and leave your team with clear reports and next steps. Whether you need a single pump overhaul, a site wide maintenance plan or live works during operation, we are ready to help.
