What Equipment Should I Invest in to Avoid Downtime?

August 18, 2025

Forecourt downtime – the period of time fuel pumps, payment systems or other important infrastructure for a forecourt are out of service – disrupts operations and can impact customer satisfaction, as well as business efficiencies. Keeping forecourts operational is key to ensuring a seamless service delivery.

In this article, we’ll explore key investments you can make to minimise downtime and protect your business from the operational, financial, and reputational costs it can bring.

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Common Causes of Downtime on Forecourts and Proactive Solutions

Although forecourt downtime can be caused by a variety of factors, it typically stems from one of two main causes: emergency repairs or the need to replace assets.

These issues are quite common with 82% of companies experiencing unplanned downtime at least once every three years. Some other common causes that are experienced are:

Equipment Malfunctions

One of the most common and disruptive causes of forecourt downtime is equipment malfunction. When key infrastructures, such as fuel dispensers or payment systems, fail, it can halt operations, frustrate customers, and lead to revenue loss.

Fuel Pump Issues

Fuel dispensers are the lifeblood of a forecourt, and any issues from malfunctioning nozzles and faulty hoses to sensor errors, can result in extended downtime. These kinds of failures often arise due to wear and tear, lack of maintenance, or outdated technology.

To minimise this risk, forecourt operators should consider investing in high-performance equipment such as the Wayne^® and Tokheim^® fuel dispenser range by Dover Fueling Solutions^® (DFS). These dispensers are specifically designed for durability, efficiency, and ease of maintenance, reducing the chances of unexpected breakdowns, and enhancing the overall customer experience.

Additionally, integrating Prizma – DFS’ connected mobility and convenience hub – allows operators to connect fuel dispensers, and other pieces of service station equipment, directly to point-of-sale (POS) systems. This integration streamlines forecourt operations, provides real-time monitoring, and enables fast responses to potential issues before they result in downtime.

Another critical tool is Remote Diagnostics and Management (RDM) by DFS. This system provides advanced remote monitoring and diagnostics across all connected forecourt equipment. With RDM, operators can perform proactive maintenance, troubleshoot problems from a distance, and schedule repairs before a fault leads to disruption. This significantly reduces unplanned downtime, optimises dispenser performance, and ensures a smoother, more reliable experience for customers.

Payment System Issues

Just as vital as fuel infrastructure are the payment systems, and when these go down, sales come to a halt. Downtime may stem from a variety of sources, such as:

Card reader failures
Errors in mobile or contactless payment systems
POS software or hardware malfunctions

Maintaining up-to-date, integrated, and secure POS systems is essential. Failures here not only prevent transactions but also damage customer trust and satisfaction.

By combining robust payment hardware with integrated platforms like Prizma, retailers gain more visibility and control over all forecourt operations. This helps mitigate issues swiftly, minimise disruptions, and create a more seamless experience for both staff and customers.

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Security Attacks

As fuel retail operations become increasingly digital, cybersecurity is no longer optional, it’s essential. With growing connectivity between payment terminals, back-office systems, dispensers, and cloud-based services, the attack surface for those with malicious intent is larger than ever. A single cyber incident can compromise sensitive customer data, disrupt transactions, and bring forecourt operations to a grinding halt.

To protect your business, it's critical to invest in comprehensive security solutions that go beyond basic protections. DFS dispensers, such as those in the Wayne and Tokheim ranges, are specifically engineered with security in mind, incorporating tamper-resistant components, intelligent multi-level access control, and integrated panel sensors to detect unauthorised access attempts. These physical security measures protect the dispenser’s core components against manipulation and fuel theft, playing a vital role in maintaining uninterrupted service and safeguarding customer trust.

Data Breaches and Hacking

Fuel retailers are particularly vulnerable to data breaches and network intrusions, especially through the forecourt’s POS systems. These systems often handle a high volume of transactions and store valuable customer and operational data, making them a prime target for cybercriminals.

To mitigate this risk, deploying secure and integrated platforms such as Prizma by DFS is a strategic first step. DFS strengthens payment protection with solutions including the Tokheim Crypto VGA^®OPT (Outdoor Payment Terminal), Wayne iX Pay^® 2 payment platform, and DFS Orion^™ indoor payment terminal, each equipped with PCI-compliant, tamper-resistant technologies. Tokheim OASE^™ further enhances security by enabling encrypted, real-time transaction monitoring through the DFS Cloud (ONE Portal). These technologies work together to deliver robust defence against data breaches and system tampering.

Fuel Theft and Anomaly Detection

Security isn’t just about data, it’s also about protecting physical assets, such as fuel. Solutions like DX Wetstock^® and ProGauge^™ automatic tank gauges (ATGs) offer advanced fuel monitoring, data analytics, and anomaly detection. ATGs allow retailers to monitor multiple tanks from a single console, providing early detection of leaks, fuel losses, or delivery discrepancies, helping operators quickly identify potential fuel theft or delivery discrepancies.

By analysing fuel flow and stock levels in real time, DX Wetstock can flag irregularities that might indicate a cyber or physical breach, such as unauthorised siphoning or manipulated meter readings. This level of intelligence helps maintain both product integrity and operational security.

Strength in Integration

The real strength lies in the combined power of DFS’ products and solutions – Prizma, DX Wetstock, ProGauge ATGs, Tokheim and Wayne fuel dispensers. Together, these technologies provide:

End-to-end encryption and secure transaction handling
Real-time system monitoring and diagnostics
Predictive alerts for potential threats or inefficiencies
Fuel inventory protection and theft prevention

By investing in these solutions, fuel retailers not only fortify their defences against security risks but also gain greater control, visibility, and resilience across the entire forecourt.

Investing in Uptime to Protect Your Business

Forecourt downtime isn’t just an inconvenience, it’s a business-critical issue that can erode revenue, customer loyalty, and operational efficiency. From equipment malfunctions to cybersecurity threats, the risks are real, but they are also manageable with the right investments.

By upgrading to reliable, future-ready fuel dispensers like those in the Wayne and Tokheim ranges, integrating intelligent systems such as Prizma for seamless operations, and utilising advanced tools like Remote Diagnostics and Management (RDM), DX Wetstock and ProGauge ATGs for predictive maintenance and fuel security, retailers can significantly reduce unplanned downtime.

Moreover, in an era where digital connectivity drives customer convenience and operational performance, security must be treated as a core pillar of forecourt resilience. Secure, integrated platforms not only protect sensitive data but also give operators the visibility and control needed to keep their forecourts running smoothly.

Ultimately, the smartest investment you can make is preventing site downtime before it happens. By taking a proactive approach – powered by innovation, integration, and real-time insights – you can protect your assets, maintain service continuity, and deliver a reliable, high-quality experience to every customer, every time.

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