The locos and car shuttles are now over 30 years old, and showing their age, and have never been refurbished from a passenger perspective (but will have had running gear overhauled no doubt). It won’t be too long before they need to be replaced, and I can’t imagine that will be cheap.
The car shuttles are receiving a mid-life refresh now, and they should all be in service by next year. They don't really have a hard life, as LeShuttle only has departures every 30 minutes outside of high season. They'll be good for another 25-30 years, as they're quite simple things.
It's quite apparent that the lorry trains emerge onto the curved terminal tracks at nothing like 140 km/h. This in itself restricts capacity. There would be some capacity gain if everything cruised at the same speed, which would have to be 140 km/h, but the reduction from this on the climb out and terminal entry reduces things further.
I believe that the curved terminal tracks are limited to 80km/h in Folkestone, slowing down to 40km/h as they approach the platforms. They're 90km/h in Calais, with the 40km/h limit applying slightly later.
It's also apparent from the way car shuttles are run that the operator's interest is running the minimum rather than maximum service. There's no published timetable to measure what is run or not, and at times of lesser demand if a round trip can be eliminated, with the cars (unknowingly) reallocated among the remainder, that happens. Presumably the same for the lorries.
Yes, this has been the way since the ferries gave them a giant black eye in the mid to late 90s. What was supposed to be a 'turn up and go' system quite quickly became an operation that worked the same way as the ferries, and they've shown little interest in expanding the boarding areas or ordering more trains.
For any normal company, initial construction loans should have been repaid by now, 30 years after completion, and day-to-day operations be cash positive, but by a series of financial manoeuvrings close to a Ponzi Scheme there are still very large amounts going out to the financial industry, who seem the principal and continuing beneficiaries of the project, while the initial promises of turn-up-and-go, both for cars and Eurostar, have been completely forgotten.
I think the entire issue is that it was privately funded from the beginning, so they were having to run a fully commercial operation against the ferries, who had the benefit of the Port of Calais being heavily subsidised and the Port of Dover essentially being able to undercut them. The company is on the right track now, but I'd be very surprised if they ever approach anything like a decent turn-up-and-go service for cars. I think they're essentially happy to work with what they've got, and to leave the rest of the car traffic to the ferries rather than trying to eliminate the ferries.
The freight service on the other hand is fantastically flexible: each ticket is valid for the day of booking, plus one day either side. They also do a lot of turn-up-and-go ticket sales, and they have a clever system in place so that if you're a regular customer with them, you can transport your truck while turn-up-and-go customers are turned away. It's quite complicated to explain, but essentially if the capacity system is used, they automatically reserve you a certain amount of tickets, even if you don't use them.
I've looked at the concessionaire agreement, and the minimum service is this:
The Fixed Link shall be open day and night. The frequency of services will be determined by the Concessionaires on a commercial basis. However, the minimum service to be maintained shall be equivalent to one tourist shuttle and one commercial freight shuttle every half hour during the day and every hour during the night.
So the 30 minute schedule for cars is the bare minimum, but for freight, they're doing considerably more than that.
Interestingly, they were also obliged to help finance the road between the RN1 and the A16 / terminal in Calais. Also interestingly, the French and British governments have the right to create a concession for a road tunnel, although they were banned from doing so before 2010 (and it wasn't allowed to open until 2020) unless it was with the agreement of Getlink. There's more information here:
https://www.theguardian.com/world/2000/jan/06/transport.uk