Reverse Engineering

Servicing AD Sites Across the UK

When critical components fail, sourcing replacement parts from overseas OEM suppliers often leads to extended lead times, higher costs, and prolonged disruption to operations. At Fletch Engineering Services, we provide a practical solution through specialist reverse engineering and OEM part replication.

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Reverse Engineering & OEM Part Replication

Downtime in anaerobic digestion (AD) plants can have a significant impact on performance, reducing output and increasing operational costs. Many plants across the UK face limited local support when urgent replacements are needed, making breakdowns even more challenging to resolve.

By manufacturing precision-engineered components in the UK, we reduce reliance on overseas suppliers and deliver the parts you need quickly to restore functionality and minimise disruption.

We offer a complete reverse engineering and manufacturing service, including:

Reverse engineering worn or failed components

Manufacturing OEM-equivalent replacement parts

Repairing and refurbishing existing equipment

Producing fully machined components to exact specifications

Whether working from original drawings or replicating existing parts, each component is manufactured to precise tolerances. Materials are carefully selected to suit high-load, abrasive, and corrosive operating environments, ensuring durability and long-term performance.

The Problem

AD plants across the UK commonly face long lead times, high replacement costs, and operational disruption when sourcing OEM parts from overseas. Equipment failures can quickly reduce efficiency and impact overall plant output.

Precision. Reliability. Performance.

Our Solution

We address these challenges by providing fast, UK-based engineering support, delivering precision-manufactured components with reduced lead times. Our approach ensures quicker turnaround, improved reliability, and minimal disruption to your operation.

Why Choose Fletch Engineering Services

We are committed to delivering dependable, high-quality engineering solutions that keep your plant running efficiently:

Precision-engineered components built for demanding conditions

Fast turnaround times to minimise downtime

Cost-effective alternatives to OEM parts

Reliable, UK-based support when you need it most

By combining expertise, quality, and responsiveness, we provide a trusted solution for maintaining performance and long-term reliability across your AD plant.

What our clients say

Fletch Engineering turned around a critical shaft repair in days. Quality was perfect and fitted as needed. Kept our AD plant running with minimal disruption. Highly reliable team.

We required precision parts and needed them delivered fast. Everything matched OEM spec exactly. Have to say, solid workmanship and the Fletch team are very easy to deal with. They are now our go-to service providers.

Professional and knowledgeable team who managed to produce custom parts from old components with no drawings. Highly impressed with both the fit and finish, excellent company to deal with!

Built Around Speed and Reliability

Quick Turnarounds

We focus on rapid turnaround for both manufactured components and repairs on anaerobic digestion sites. In many cases we can produce replacement parts such as digester screws in one to two weeks, compared with typical OEM lead times of twelve to fourteen weeks.

Extensive Knowledge Across Our Team

Our team has developed extensive knowledge of AD plant equipment and the challenges operators regularly face. This allows us to identify issues quickly, understand the demands placed on each component, and manufacture or repair parts with confidence.

Solutions Focused

Every plant and every piece of equipment presents slightly different challenges. Components often fail due to wear, operational conditions, or unique design characteristics. Our approach is focused on practical problem solving. We assess the component, understand the cause of the issue, and manufacture or repair the part to ensure it performs reliably once returned to service.

Complete our enquiry form and our team will be in touch

Frequently asked questions

When is reverse engineering typically required?

It is commonly used when original drawings are unavailable, parts are obsolete, or replacements are no longer supplied. It allows critical components to be reproduced without relying on OEM support.

How are accurate replacements produced without drawings?

We use detailed measurement techniques combined with our in-house CAD capability to recreate components. This ensures replacements match the original function, with the option to improve design where needed.