7 Common Reasons Food Trucks Fail Their CP44 Gas Safety Inspection

Whether you operate a coffee van, burger trailer, horsebox conversion or mobile catering unit, obtaining a valid CP44 Gas Safety Certificate is an essential part of trading safely. Not only is it often required by event organisers, local authorities and organisations such as NCASS, but it also provides reassurance that your gas system is operating safely for you, your staff and your customers.

At Wirral Gas, we've inspected a wide variety of mobile catering units over the years, and although every setup is different, we often encounter the same recurring issues. Fortunately, many of these can be avoided with regular servicing and professional installation.

1. Appliances are fitted with the wrong gas injectors

One of the most common—and potentially dangerous—issues we come across is appliances that have not been correctly converted from Natural Gas to LPG.

Many commercial fryers, griddles, ovens and other catering appliances are manufactured to run on Natural Gas (NG). Before they can be safely installed in a mobile catering unit, they must be converted using the manufacturer's approved LPG conversion kit, which typically includes replacing the gas injectors.

Unfortunately, it's not uncommon to find appliances that have simply been connected to an LPG system without this conversion taking place. Running Natural Gas injectors on an LPG supply can cause poor combustion, unstable flames, excessive carbon monoxide production and unsafe appliance operation. During a CP44 inspection, this type of installation would not meet the required safety standards and would require rectification before certification can be issued.

2. Worn or damaged flexible gas hoses

Flexible gas hoses have a finite lifespan and are subjected to far more movement and wear in a mobile catering environment than in a fixed commercial kitchen. Every journey to an event places additional strain on the gas installation, making regular inspections particularly important.

Over time, hoses can become cracked, perished, kinked or damaged through abrasion. In some cases, we also find hoses that are simply the wrong type for the appliance or installation. Even if a hose appears to be functioning normally, deterioration can increase the risk of leaks and should never be ignored.

3. Gas leaks within the installation

Even a very small gas leak is enough to fail a CP44 inspection.

Gas leaks can develop around compression fittings, appliance connections, isolation valves, regulators or pipework joints. In many cases they aren't noticeable during normal day-to-day use, which is why professional tightness testing forms such an important part of every inspection.

Identifying and repairing minor leaks early not only ensures compliance but also prevents them from developing into much more serious safety issues.

4. Unsafe LPG cylinder installations

The LPG cylinder installation is one of the first things we assess during an inspection, yet it is an area where we regularly identify problems.

Cylinders should be securely restrained, properly ventilated and fitted with suitable regulators and connecting hoses. We occasionally find cylinders that have simply been placed inside a compartment without adequate restraint, or installations where damaged pigtails and incorrect regulators have been fitted. Because LPG is heavier than air, any leak can accumulate in low areas if ventilation is inadequate, making correct cylinder installation critical to the overall safety of the catering unit.

5. Missing or faulty safety devices

Modern catering gas systems are designed with several safety features that help protect both operators and customers. Depending on the equipment installed, this may include flame failure devices, emergency isolation valves, gas interlocks and pressure regulators.

These components are there for a reason. If a safety device is missing, damaged or no longer functioning correctly, the installation may no longer comply with current safety requirements. During a CP44 inspection, we'll always verify that these devices are present, suitable and operating as intended.

6. Poor installation or unauthorised modifications

Mobile catering businesses often evolve over time. New appliances are added, layouts are altered and equipment is replaced as businesses grow.

Unfortunately, not every modification is carried out by a suitably qualified engineer. We regularly come across pipework that has been poorly supported, incorrect fittings that have been used, or appliances that have been connected without proper testing and commissioning.

Although these alterations may appear to work perfectly well, they can introduce hidden safety risks that only become apparent during a full inspection.

7. A lack of routine servicing and maintenance

Perhaps the biggest reason we see preventable failures is simply a lack of routine maintenance.

Many businesses wait until their annual CP44 inspection before having their gas system looked at. By that point, components may have worn, fittings may have loosened during transport and appliances may no longer be operating as efficiently or safely as they should.

Having your catering unit serviced throughout the year allows potential issues to be identified and corrected before they become reasons for failing an inspection. It also helps reduce the likelihood of unexpected breakdowns during busy trading periods, when downtime can be particularly costly.

Failing a CP44 Gas Safety Inspection doesn't necessarily mean your catering unit is unsafe beyond repair. In many cases, the issues identified are straightforward to rectify when they're caught early. Regular servicing, correct installation and using suitably qualified engineers all play an important role in keeping your business safe, compliant and ready to trade.

At Wirral Gas, we specialise in CP44 Gas Safety Inspections, LPG installations, servicing and repairs for food trucks, trailers, horseboxes and mobile catering units across the North West.

Whether you're preparing for your annual inspection or simply want the reassurance that your system is operating safely, our experienced engineers are here to help.