Retrofit Strategies – Upgrading Manual Dispensers to Automatic Systems in Existing Facilities

A retrofit succeeds when it improves measurable operations:

• Fewer repeat calls (drips, clogs, false triggers, empty units)
• Faster service cycles (refill + battery change without disassembly)
• Better user experience (clear activation zone; consistent dose)
• Cleaner surroundings (less splatter, less residue)

In healthcare and other high-risk environments, your soap dispenser workflow is part of a broader hygiene program—handwashing is a foundational control.

A) Mounting strategy: wall vs deck

Wall-mounted retrofits are often simpler to standardize, but demand reliable backing and waterproof penetrations. Deck-mounted retrofits can look cleaner in premium restrooms, but require under-counter access and accurate hole sizing.

Retrofit tip: don’t assume the existing hole pattern can be reused—confirm template compatibility before ordering.

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B) Soap type and viscosity

Most early failures trace back to soap incompatibility (viscosity and additives) that stresses pumps/nozzles.

Best practice for existing facilities:

• Standardize on one soap type per building (liquid or foam)
• Document the approved SKU(s) and train housekeeping to avoid substitutions

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C) Power: battery vs plug-in vs hardwired

• Battery: fastest retrofit; predictable if you track replacement cycles
• Plug-in transformer: reduces battery calls; requires an accessible outlet and clean routing
• Hardwired low-voltage: best for high traffic if you can maintain access (avoid “buried” transformers)

Decision rule: choose power based on traffic + service access, not preference.

In existing restrooms, failures come from conditions no one documented:

• Wall substrate and backing are unknown
• Counter thickness varies by room
• Under-sink cabinetry blocks service access
• Mirrors/metal backsplashes create sensor reflections

What to capture in a 15-minute survey:

• Mount location, clearances, and conflicts (towel, dryer, grab bars)
• Under-counter access (for deck mounts and power components)
• Cleaning chemicals used on/near the unit (finish and sensor window risk)
• Sunlight or highly reflective surfaces near activation zone

Use the printable Retrofit Readiness Survey (below) to standardize this walk.

Two practical retrofit principles:

• Operable parts must be usable without tight grasping/pinching/twisting and with limited force—your retrofit should avoid “fussy” latches or awkward manual overrides.
• If soap dispensers are provided at lavatories, they must be located within required reach ranges. (This is frequently missed when moving units during renovation.)

Retrofit habit that prevents rework: confirm the final dispenser location and user approach (forward/side) during the field survey—not after rough-in.

Strategy A: “1:1 swap” (same general location)

Best when the existing location is good and the new unit covers old penetrations.

Key steps:

• Verify backing (don’t trust tile alone)
• Seal penetrations properly in wet zones
• Ensure the dispenser is plumb/level (rocking = callbacks)

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Strategy B: “Relocate and patch”

Best when the existing location conflicts with accessibility, mirrors, or towel equipment.

Key steps:

• Patch/finish is part of the scope—don’t leave it “TBD”
• Re-check sensor behavior in the new location (reflections change)

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Strategy C: Deck-mount conversion

Best in premium restrooms or when wall construction is problematic.

Key steps:

• Confirm hole size + deck thickness
• Ensure service access for battery/reservoir
• Route tubing to avoid tight bends and pinch points

A dispenser is not complete when it turns on. It’s complete when it:

• Primes and dispenses consistently (5–10 cycles)
• Has a predictable activation distance (no hunting)
• Does not false-trigger (mirrors/metal backsplashes are common causes)
• Stops cleanly (no drip trail)
• Can be refilled and serviced without uninstalling anything

Use the Commissioning & Ops Logbook (below) to record the settings that worked in that room—this dramatically speeds up future troubleshooting.

A strong retrofit plan includes a basic O&M model:

• Define inspection interval by traffic (daily/weekly/monthly)
• Stock spares (batteries, pump modules/keys)
• Standardize models and soaps to reduce variability
• Train housekeeping on sensor-safe cleaning (avoid harsh abrasives on the sensor lens)

For broader facility hygiene programs—including surface cleaning/disinfection protocols—align restroom maintenance with CDC guidance on cleaning and disinfecting facilities.

For each dispenser type and location:

• Cut sheets/submittals and final model IDs
• Installation and maintenance instructions
• Warranty terms and spare parts list
• Asset tagging plan (room ID + model + power type)
• Commissioning record (dose/sensor zone acceptance)

These documents prevent your team from “guessing” after turnover.