For many car wash owners, the in-bay automatic model is a familiar and reliable starting point. It can be compact, efficient and relatively simple to operate. But when a site reaches capacity, the same model that helped build the business can start to limit its growth.
That was the challenge at an in-bay automatic car wash in Bainbridge, Georgia. The site was washing approximately 40,000 cars per year and had reached capacity. The owner wanted to increase throughput without starting from scratch, so the existing in-bay automatic system was removed and replaced with an AVW mini tunnel.
The result was a major change in both capacity and wash flow. The site moved from roughly 20 cars per hour to an estimated 40 to 60 cars per hour, creating a more productive operation inside the same general footprint.
For operators considering a similar move, this project highlights both the opportunity and the planning required when converting an in-bay automatic into a mini tunnel.
Why Convert an In-Bay Automatic?
The biggest reason to consider an in-bay conversion is throughput.
An in-bay automatic typically washes one vehicle at a time. That can work well for lower-volume sites, but once demand grows, the system may become the bottleneck. Lines get longer, customers wait longer and the site cannot process more vehicles without a different wash format.
A mini tunnel changes that equation by creating continuous vehicle movement through the wash process. Instead of one car entering, stopping, washing and exiting before the next begins, a tunnel-style layout allows vehicles to move through more efficiently.
For the Bainbridge project, the owner’s goal was clear: increase throughput at a site that was already performing well but had reached the limits of the existing equipment.
The Equipment Package
The conversion included a surface-mount AVW belt conveyor and a compact tunnel equipment package designed to fit the application.
The package included:
- 60-foot surface-mount AVW belt conveyor
- Double wrap mitter contour combo
- High-pressure oscillating arch
- Mini mitter
- 10 dryers
- Three applicator arches
- New motor control center and controller
- New chemical application stations
- Pump system to power the pivoting wheel blaster and high-pressure oscillating arch
Together, these components helped turn the existing in-bay space into a more capable mini tunnel wash. The goal was not just to fit more equipment into the building, but to create a wash process that could handle more vehicles while maintaining strong wash quality.
The Throughput Impact
Before the conversion, the in-bay automatic was processing approximately 20 cars per hour. After the mini tunnel installation, throughput increased to roughly 40 to 60 cars per hour.
That kind of increase can significantly change the business potential of a site. More cars per hour means the operation can better serve peak demand, reduce bottlenecks and create more opportunity for revenue growth.
For owners who already have strong traffic but feel limited by equipment capacity, an in-bay conversion may offer a practical path forward. It allows the site to evolve from a single-car wash process into a higher-volume operation without necessarily requiring a full new build.
What to Consider Before Installing a Surface-Mount Conveyor
A surface-mount conveyor can make an in-bay conversion possible, but it requires careful planning. Because the conveyor sits above the existing floor, several site-specific details need to be reviewed before installation.
1. Drain Placement
Drain placement is one of the first things to evaluate. The drain needs to be positioned so it does not interfere with the conveyor or create issues for customers and employees walking around the equipment.
On this project, the conveyor had to be shifted two inches toward the passenger side to accommodate the drain location. That kind of adjustment is manageable when it is identified early, but it can create problems if it is not accounted for during layout planning.
2. Anchoring Into Existing Concrete
Unlike new construction, an existing in-bay facility may not have embeds in the floor for welding equipment into
place. That means every mounting point may need to be drilled and anchored into the concrete.
This can increase installation time and should be factored into the project schedule. It is not necessarily a reason to avoid conversion, but it is a detail owners should understand before the work begins.
3. Longer Equipment Legs
Because a surface-mount conveyor raises the vehicle path, the surrounding equipment may also need to be raised to the proper operating height.
When ordering equipment for this type of project, longer legs may be required. In this case, the raised conveyor meant the equipment needed additional leg length to achieve the correct height.
This is a simple but important detail. If it is missed during planning, it can create avoidable delays during installation.
4. Wall-to-Wall Grating
For a clean, finished appearance and safe access around the raised conveyor, wall-to-wall grating may be needed.
The grating must be planned carefully. It needs to fit around each equipment leg, provide proper support and still allow access for service. Since the belt conveyor will need maintenance over time, the grating should be removable where service access is required.
A good conversion is not only about getting the equipment installed. It also needs to be serviceable after the installation is complete.
5. Ceiling Height
Ceiling height can become a major constraint in an in-bay conversion.
Because the conveyor and equipment may sit higher than they would in a traditional tunnel layout, the building needs enough vertical clearance for raised equipment. On the Bainbridge project, clearance was tight, with only about one inch to spare.
Before moving forward with a conversion, owners should verify ceiling height and confirm that the selected equipment can operate safely and effectively within the available space.
6. Loading and Unloading Ramps
A surface-mount conveyor also requires proper ramps for loading and unloading vehicles.
The ramps need enough space and the proper slope to create a smooth customer experience. If the approach is too steep or awkward, loading can become difficult, especially for customers who are not used to conveyor-style washing.
This is especially important for former in-bay sites, where customers may be accustomed to simply pulling into the bay and stopping.
Customer Retraining Matters
One of the most important lessons from an in-bay conversion is that the equipment is only part of the transition.
Customers who are used to an in-bay automatic may not immediately understand how to load onto a belt conveyor. They may need clearer signage, attendant guidance and time to adjust to the new process.
For owners, this means the launch plan should include customer education. The first few weeks after conversion may require more hands-on support from staff to help customers learn the new flow.
The same is true for the owner and team. A mini tunnel creates different operating habits than an in-bay automatic. Loading, monitoring, maintenance and customer communication all become part of the new process.
Is an In-Bay Conversion Right for Every Site?
Not every in-bay automatic is a good candidate for conversion. The right answer depends on the building, traffic volume, ceiling height, drainage, concrete condition, available ramp space and business goals.
But for the right site, a mini tunnel conversion can be a powerful way to increase capacity without abandoning an existing location.
The Bainbridge project shows what is possible when a high-performing in-bay automatic reaches its limit. By converting the site into a mini tunnel with a surface-mount belt conveyor, the owner was able to increase throughput, improve flow and create a more scalable wash operation.
For car wash owners asking whether they can get more out of an existing in-bay site, the answer may be yes: but the details matter.
A successful conversion starts with understanding the building, planning around the site constraints and choosing equipment that can deliver the desired throughput while still being practical to install, operate and maintain.
Considering an In-Bay Conversion?
AVW works with operators to evaluate equipment layouts, conveyor options and tunnel configurations for new builds, retrofits and conversion projects. If your in-bay automatic has reached capacity, a mini tunnel layout may help you move more vehicles through your wash while making better use of your existing site.
