BRITANX Process has completed the manufacture of a bespoke 600-litre stainless steel vessel for a specialist industrial heating and cooling test rig.

Manufactured at Fabdec’s factory in Ellesmere, Shropshire, the vessel demonstrates our ability to develop tailored temperature-control solutions for demanding industrial applications.

Unlike conventional storage vessels, this unit has been designed to accommodate both heating and cooling functions. As a result, it offers the flexibility required for controlled thermal testing.

Designed for Specialist Heating and Cooling Applications

The customer required a stainless steel vessel capable of supporting a heating and cooling test rig. The system was specified to operate using a mixture of water and ethylene glycol.

This fluid mixture is commonly used in temperature-control systems because it provides protection against freezing at sub-zero temperatures.

To accommodate the application, BRITANX manufactured a bespoke 600-litre vessel with provisions for both heating and cooling equipment.

The design incorporates an internal stainless steel cooling coil arrangement, allowing heat to transfer between the vessel contents and a separate cooling circuit.

Additionally, the vessel features multiple flanged connections to accommodate the required pipework and associated equipment.

A Bespoke Stainless Steel Construction

The vessel incorporates several features tailored to the customer’s requirements.

These include:

• 600-litre capacity: Providing the required volume for the industrial test rig.
• Stainless steel construction: Using corrosion-resistant materials suited to demanding process environments.
• Internal cooling coils: Providing a heat transfer surface for cooling the vessel contents.
• Heating provisions: Connections designed to accommodate electric immersion heating equipment.
• Flanged connections: Supporting integration with the customer’s existing test equipment and pipework.
• External insulation: Helping to reduce unwanted heat transfer between the vessel and its surroundings.

The vessel also features a maximum working pressure of 6 bar, providing a robust construction for the intended application.

Each component has been incorporated to meet the specific requirements of the customer’s testing system.

Supporting Industrial Research and Development

Heating and cooling test rigs play an important role in industrial research, product development and equipment validation.

By creating controlled temperature conditions, these systems can help engineers evaluate performance across different operating environments.

However, standard vessels may not provide the necessary connection arrangements, heating provisions or cooling capabilities for specialist testing applications.

Therefore, bespoke manufacturing offers an opportunity to develop equipment around the requirements of an individual project.

For this application, BRITANX combined stainless steel vessel manufacturing with specialist temperature-control features to produce a tailored solution.

Bespoke Process Vessels from BRITANX

At BRITANX Process, we manufacture stainless steel vessels for a wide range of industrial applications.

From heating and cooling vessels to mixing, storage and specialist pilot-scale equipment, our team works with customers to develop solutions around their process requirements.

Our manufacturing capabilities allow us to accommodate bespoke connection arrangements, internal components and specialist thermal-control systems.

Do you require a bespoke stainless steel vessel for an industrial application?

Contact the BRITANX Process team to discuss your requirements and discover how our British manufacturing expertise can support your next project.

Temperature control is essential across many industrial processes, from cooling food products to maintaining consistent temperatures in chemical manufacturing. One technology used to achieve efficient heat transfer is the pillow plate heat exchanger.

Pillow plates are specially manufactured stainless steel panels that allow heating or cooling fluids to circulate through internal channels, transferring thermal energy between the fluid and the surrounding process.

But how exactly do pillow plate heat exchangers work, and what makes them suitable for such a wide range of industrial applications?

What Is a Pillow Plate Heat Exchanger?

A pillow plate heat exchanger consists of two stainless steel sheets welded together in a carefully designed pattern. The sheets are then inflated under controlled pressure, creating a series of internal channels through which a heating or cooling medium can circulate.

The inflation process creates the distinctive raised, pillow-like surface from which the technology takes its name.

Unlike conventional heat exchangers, which may rely on tubes or gasketed plate assemblies, pillow plates can be manufactured in different shapes and configurations. This makes them particularly useful for applications where heat transfer surfaces need to fit around or inside existing equipment.

They can be incorporated into process vessels, cooling tanks, industrial chillers and other equipment requiring controlled heating or cooling.

How Does a Pillow Plate Heat Exchanger Work?

The operating principle is relatively straightforward. A heating or cooling medium flows through the internal channels of the pillow plate, while the product or fluid requiring temperature control remains on the opposite side of the stainless steel surface.

Heat passes through the metal, allowing thermal energy to move between the two fluids without them coming into direct contact.

For example, when chilled water circulates through a pillow plate, heat from a warmer product transfers through the stainless steel into the cooling water. The warmed water then leaves the plate, allowing the cooling process to continue.

The same principle can be reversed for heating applications, where hot water or another suitable heating medium transfers thermal energy into the surrounding product.

The distinctive channel design also encourages fluid movement and mixing within the plate, helping to support effective heat transfer across its surface.

How Are Pillow Plates Manufactured?

Manufacturing pillow plates requires precise welding and controlled forming processes.

1. Stainless Steel Preparation

Two stainless steel sheets are prepared according to the dimensions, thickness and configuration required for the application.

2. Laser Welding

The sheets are joined using a carefully programmed laser welding pattern. The arrangement of welds determines the internal flow paths and helps provide structural support.

3. Pressure Inflation

Once welded, the plates are inflated under controlled pressure. The unwelded sections expand to create the internal channels that will carry the heating or cooling medium.

4. Finishing and Inspection

Connections and any required finishing operations are completed, with the finished plates inspected and tested according to their intended operating requirements.

The result is a fully welded heat transfer surface that can be integrated into a wide variety of industrial systems.

What Are the Advantages of Pillow Plate Heat Exchangers?

Pillow plate technology offers several advantages for industrial heating and cooling applications.

• Effective Heat Transfer: The internal channel geometry encourages fluid mixing, supporting efficient heat exchange.
• Flexible Design: Plates can be manufactured in different dimensions, shapes and configurations to suit specific applications.
• Compact Construction: Pillow plates can provide substantial heat transfer surface area without requiring bulky external equipment.
• Stainless Steel Durability: Stainless steel construction provides strength and corrosion resistance for suitable industrial environments.
• Versatile Integration: Plates can be incorporated into vessel jackets, immersion systems, chillers and bespoke heat exchangers.

The exact thermal performance depends on factors including plate geometry, flow rates, operating temperatures and the properties of the fluids involved.

Where Are Pillow Plate Heat Exchangers Used?

Pillow plates are used across several industries where reliable temperature control is essential.

Food and Beverage Processing

Temperature control plays an important role in food manufacturing, particularly when products need to be heated, cooled or maintained within a specific temperature range.

Pillow plates can be incorporated into stainless steel process vessels to provide controlled heating and cooling during production.

Dairy Cooling

Pillow plate technology can be used in dairy cooling equipment, including falling film chillers, dairy tanks and other systems designed to transfer heat from water or milk cooling circuits.

These applications benefit from configurable heat transfer surfaces designed around the required cooling duty.

Chemical and Pharmaceutical Manufacturing

Many chemical and pharmaceutical processes require carefully controlled temperatures during mixing, storage or processing.

Pillow plate jackets and integrated heat exchangers can provide heating or cooling while keeping the thermal transfer medium separate from the product.

THERMOPLATES: Manufactured by Fabdec

At Fabdec, we manufacture stainless steel pillow plate heat exchangers in-house under our THERMOPLATES range.

Using our dedicated laser welding equipment at our manufacturing facility in Ellesmere, Shropshire, we can produce bespoke pillow plates measuring up to 6 metres by 2 metres.

Our manufacturing capabilities allow us to tailor plate dimensions, internal flow paths and configurations to meet specific heating and cooling requirements.

THERMOPLATES can be supplied as standalone heat exchangers or integrated directly into Fabdec-manufactured equipment, including bespoke BRITANX process vessels, tank jackets and industrial chillers.

By combining in-house pillow plate manufacturing with our wider stainless steel fabrication expertise, we can develop heat transfer solutions around the requirements of individual applications.

Discover Fabdec THERMOPLATES

From industrial temperature control to bespoke process vessel manufacturing, pillow plate heat exchangers provide a versatile solution for a wide range of heating and cooling applications.

To learn more about our manufacturing capabilities, explore our THERMOPLATES range or contact the Fabdec team to discuss your requirements.

BRITANX Process, part of Fabdec Group, has manufactured two bespoke 7,000-litre stainless steel yeast storage vessels for a major UK bread manufacturer. Designed to support large-scale bakery production, the vessels incorporate THERMOPLATE cooling jackets and integrated agitators to maintain controlled storage conditions for liquid yeast.

With a combined storage capacity of 14,000 litres, the vessels demonstrate BRITANX’s capabilities in manufacturing specialist process equipment for the food and beverage industry.

The Importance of Yeast Storage in Bread Production

Yeast plays an essential role in bread production, converting sugars into carbon dioxide during fermentation and allowing dough to rise. In large-scale commercial bakeries, maintaining yeast quality and consistency is particularly important for reliable production.

Many industrial bakeries use liquid yeast, also known as cream yeast, which can be stored in bulk and accurately dosed into production equipment.

However, as a living microorganism, yeast requires carefully controlled storage conditions. Temperature fluctuations and prolonged periods without mixing can affect its condition and consistency, making specialist storage vessels an important part of industrial bakery operations.

Maintaining Temperature with THERMOPLATE Technology

Each of the two 7,000-litre vessels incorporates a THERMOPLATE cooling jacket, designed to facilitate heat transfer and maintain controlled temperatures within the vessel.

Liquid baker’s yeast is typically stored under refrigerated conditions, commonly around 4°C, to help preserve its activity and quality.

By circulating a cooling medium through the THERMOPLATE jacket, heat can be transferred away from the stored yeast, helping maintain the required process temperature.

This temperature management is particularly important in large-capacity storage applications, where maintaining consistent conditions across significant volumes of product is essential.

Keeping Yeast Consistent Through Agitation

Alongside temperature control, each vessel features an integrated agitator to keep the liquid yeast moving during storage.

Without sufficient mixing, yeast cells can gradually settle, creating an uneven concentration throughout the vessel. This can lead to inconsistencies when yeast is transferred or dosed into the bread-making process.

The agitators help maintain a homogeneous mixture, keeping yeast cells suspended and supporting consistent product handling.

Together, the cooling jackets and agitation systems provide two important functions for maintaining liquid yeast during industrial storage.

Bespoke Process Vessels for the Food Industry

Manufactured at Fabdec’s facility in Ellesmere, Shropshire, the twin vessels highlight BRITANX’s ability to deliver bespoke stainless steel equipment for specialist food processing applications.

From storage vessels and mixing systems to heating, cooling and fermentation equipment, BRITANX manufactures process vessels designed around individual production requirements.

The combination of large-capacity storage, integrated agitation and THERMOPLATE heat transfer technology demonstrates how multiple process requirements can be incorporated into a single vessel design.

Looking for a bespoke stainless steel process vessel?

Explore our range of BRITANX Process Vessels or contact the Fabdec team to discuss your application.

Maintaining milking equipment is essential for efficient dairy operations, milk quality and herd health. One component that can easily be overlooked is the teat cup liner. Knowing when to replace milking liners can help farmers maintain consistent milking performance and reduce the risks associated with worn equipment.

Why Is Regular Liner Replacement Important?

Milking liners are the only part of the milking machine that comes into direct contact with a cow’s teats. Their condition therefore plays an important role in both milking efficiency and udder health.

Over time, regular use and exposure to cleaning chemicals can cause liners to lose their elasticity, deteriorate or develop small cracks. These changes can affect the way liners function during milking, potentially leading to longer milking times, inconsistent performance and increased hygiene risks.

Replacing liners at appropriate intervals is an important part of preventative milking parlour maintenance.

When Should Milking Liners Be Replaced?

As a general guideline, conventional rubber-based milking liners should be replaced after approximately 2,500 milkings or six months, whichever comes first.

However, replacement intervals will vary depending on factors including:

• The number of cows being milked
• The number of milkings carried out each day
• The number of milking clusters in operation
• The material and manufacturer’s recommended lifespan of the liners

For larger herds or parlours operating more frequently, liners may reach their recommended usage limit considerably sooner than six months.

Silicone liners can offer longer service intervals, although the manufacturer’s recommendations should always take priority.

How to Calculate Your Liner Replacement Interval

To establish an appropriate replacement schedule, farmers can calculate the approximate number of milkings performed by each cluster every day.

For example, consider a dairy farm operating with the following equipment and milking routine:

With 140 cows milked twice daily, the parlour performs 280 cow milkings each day.

Dividing this figure by the 10 available clusters gives an average of 28 milkings per cluster per day.

At a recommended lifespan of 2,500 milkings, the calculation is:

2,500 ÷ 28 = approximately 89 days

In this example, the farm should plan to replace its milking liners approximately every three months, rather than waiting for the six-month maximum.

This demonstrates why replacement schedules should be based on actual parlour usage rather than a fixed calendar interval alone.

Recognising Signs of Worn Milking Liners

While calculating replacement intervals provides a useful maintenance schedule, farmers should also check liner condition regularly.

Signs that milking liners may require attention include visible cracking, loss of elasticity, physical damage or an increase in liner slips.

Deteriorating liners can also make effective cleaning more difficult, as damaged surfaces may harbour bacteria.

Regular inspections, combined with a planned replacement schedule, can help identify potential problems before they affect milking operations.

Planning Ahead with a Liner Replacement Calculator

Keeping track of liner usage becomes increasingly important as herd sizes, milking frequency and parlour configurations change.

A liner replacement calculator simplifies this process by using the farm’s operating information to estimate how frequently liners should be replaced.

By entering the number of cows, daily milkings, available clusters and recommended liner lifespan, farmers can establish a replacement interval tailored to their milking routine.

Keeping a record of the last replacement date also makes it easier to schedule the next change and ensure routine maintenance is not overlooked.

Supporting Efficient Dairy Operations

Effective milking parlour maintenance extends beyond the performance of individual components. Regular inspections, appropriate replacement intervals and well-maintained equipment all contribute to reliable daily operations.

Understanding when to replace milking liners is a straightforward but valuable part of this process.

Fabdec Dairy Systems supports dairy farmers with practical equipment and solutions designed for the demands of modern milk production.

For more information about our dairy equipment and solutions, explore the Fabdec Dairy Systems range or contact our team.

Fabdec Dairy Systems is preparing to exhibit at EuroTier 2026, taking place from 10–13 November at the Hanover Exhibition Centre in Germany.

Recognised as one of the world’s leading trade fairs for professional animal farming and livestock management, EuroTier brings together manufacturers, agricultural professionals and industry specialists from across the globe to explore the latest developments in farming technology.

With a strong presence in the international dairy sector, Fabdec is looking forward to returning to Germany to connect with customers, distributors and industry partners.

Showcasing Dairy Cooling Expertise

Throughout the four-day exhibition, the Fabdec Dairy Systems team will be available to discuss our extensive range of milk cooling, storage and farm equipment solutions.

From bulk milk tanks and pre-cooling systems to heat recovery and dairy farm equipment, our products are designed to support the varying requirements of modern dairy operations.

With decades of experience manufacturing stainless steel dairy equipment, Fabdec continues to supply solutions to farms and dairy installations across Europe and beyond.

EuroTier provides an excellent opportunity to discuss these technologies directly with the people who use, install and distribute them.

Strengthening Our European Connections

Germany and the wider European market remain important to Fabdec Dairy Systems, making EuroTier a valuable opportunity to strengthen existing relationships and develop new connections within the industry.

Our team looks forward to meeting dairy farmers, equipment dealers and industry professionals to discuss their requirements, share technical knowledge and explore opportunities for future collaboration.

As dairy farming continues to evolve, maintaining close relationships with our international customers helps us understand the changing demands placed on milk cooling and storage equipment.

Visit Fabdec at EuroTier 2026

EuroTier 2026 takes place from 10–13 November at the Hanover Exhibition Centre in Germany.

You’ll find Fabdec Dairy Systems in Hall 13, Stand E19, where our team will be available throughout the exhibition to discuss our range of milk cooling, storage and dairy farm equipment solutions.

Whether you’re an existing customer, distributor or looking to explore new dairy cooling technologies, we look forward to welcoming you to our stand.

Hall 13 | Stand E19 | 10–13 November 2026

Find out more about our Dairy Systems range or visit the official EuroTier website.

Fabdec’s Energy Blades are typically used in heat recovery applications, transferring thermal energy from natural water sources such as ponds and lakes into heat pump systems.

However, a recent manufacturing project at our Ellesmere factorye has demonstrated a different application for this technology, with a specially configured Energy Blade assembly being produced for use at a commercial carrot processing facility.

Rather than recovering heat from the surrounding environment, these Energy Blades will perform the opposite function, actively cooling water through a refrigerant-based system.

A New Application for Energy Blade Technology

Temperature control is an important consideration in food processing, particularly where heated water is used during production.

For this project, the Energy Blades will be used to cool hot water involved in carrot processing, helping to bring the carrots down to the required temperature.

Unlike conventional Energy Blade installations, where heat is extracted from a natural water source, this system uses refrigerant circulating through the internal channels of the stainless steel pillow plates to absorb heat from the surrounding water.

This follows a similar cooling principle to that used in Fabdec’s refrigerated milk tanks, where refrigerant circulating through stainless steel cooling surfaces removes heat from the milk.

The result is a different use of the same underlying heat exchange technology, demonstrating how Energy Blades can be configured for both heat recovery and active cooling applications.

Manufactured Using In-House Pillow Plate Technology

The assembly has been manufactured at Fabdec’s Ellesmere facility, using our in-house laser-welded pillow plate technology.

Each stainless steel plate incorporates internal channels for refrigerant circulation, creating an extensive heat transfer surface while maintaining a compact arrangement.

Multiple plates are brought together into a single assembly, complete with connecting pipework designed for integration into the wider refrigeration system.

Fabdec’s in-house pillow plate manufacturing capabilities allow us to produce heat exchange surfaces for a range of applications, from dairy cooling and process vessels to energy recovery and industrial refrigeration.

Expanding the Possibilities of Energy Blades

Although Energy Blades are traditionally associated with heat recovery from ponds and lakes, this project highlights their potential for use in dedicated industrial cooling systems.

By changing how the technology is applied, the same fundamental stainless steel heat exchanger design can be used to remove heat from process water rather than recover it for heating purposes.

For Fabdec, this latest project demonstrates the versatility of our Energy Blade technology and our ability to manufacture bespoke thermal solutions for applications beyond their conventional uses.

As requirements for temperature control continue across the food processing and wider industrial sectors, applications such as this highlight further opportunities for stainless steel pillow plate heat exchangers.

Discover more about our Energy Blades and pillow plate manufacturing capabilities, or contact our team to discuss your industrial cooling requirements.

Process vessels can remain in service for many years, but that does not always mean they continue to suit the needs of a growing brewery.

Changes in production volume, recipes, cleaning requirements and temperature control can gradually expose limitations in older or undersized equipment. In some cases, upgrading a vessel can improve efficiency, increase capacity and make the overall brewing process easier to manage.

So, when should a brewery consider upgrading its process vessels?

Production Capacity Is Becoming a Bottleneck

One of the clearest signs is when existing vessels begin to restrict production.

Fermentation and conditioning can occupy vessels for long periods, so limited tank capacity can quickly create delays elsewhere in the process.

Common signs include:

• Fermentation vessels remaining continuously occupied
• Production schedules becoming harder to manage
• Batches being delayed while waiting for vessel availability
• Demand exceeding practical production capacity

Adding larger vessels or increasing the number of available tanks can help improve throughput and give the brewery greater flexibility.

Temperature Control Is No Longer Consistent

Accurate temperature control is particularly important during fermentation, conditioning and other temperature-sensitive stages of brewing.

If vessels take too long to heat or cool, or struggle to maintain a stable temperature, this can affect both production efficiency and product consistency.

Modern vessels can incorporate heating and cooling surfaces designed around the process itself. Laser-welded pillow plate jackets, for example, can provide effective heat transfer across the vessel surface while remaining integrated into the vessel design.

Improved temperature control can also reduce process times and help vessels become available sooner for the next batch.

Cleaning and Hygiene Are Becoming Harder to Manage

Hygienic design is essential in brewery environments.

As equipment ages, internal surfaces, fittings and pipework may become more difficult to clean effectively. Older vessels may also require more manual cleaning than equipment designed around modern CIP processes.

An upgraded vessel can incorporate:

• Hygienic internal finishes
• CIP spray devices
• Improved drainage
• Hygienic fittings and connections
• Reduced areas where product can collect

These features can make cleaning more consistent and help reduce manual intervention between batches.

Maintenance Requirements Are Increasing

Stainless steel process vessels are designed for long service lives, but repeated maintenance can eventually become a sign that replacement should be considered.

Problems with valves, jackets, insulation, fittings or other components can increase downtime and maintenance costs over time.

If repairs become frequent, replacing the vessel may provide an opportunity to improve the specification rather than simply maintaining equipment that no longer suits the process.

Your Brewing Process Has Changed

Breweries often evolve over time.

New products, changes in batch size, different carbonation methods or revised fermentation processes can all place different demands on process equipment.

A vessel originally designed for storage, for example, may not have the pressure rating, temperature control or fittings required for a new application.

In these situations, a bespoke vessel designed around the current process can often provide a better long-term solution than adapting older equipment.

Planning for Future Growth

It is often better to review vessel capacity before it becomes a serious production constraint.

When specifying new equipment, breweries should consider not only current demand but how production may change in the future.

Factors such as batch size, production frequency, available floor space, cooling capacity and future product ranges can all influence vessel specification.

Planning ahead can make future expansion easier and reduce the risk of new equipment quickly becoming undersized.

Bespoke Brewery Process Vessels from BRITANX

BRITANX manufactures bespoke stainless steel process vessels for food and beverage applications, including mixing, heating and cooling, fermentation, carbonation, buffer storage and product storage.

With in-house fabrication and pillow plate laser welding capability, vessels can be designed around the required capacity, temperature control, pressure rating, fittings and production environment.

Whether replacing ageing equipment or increasing brewery capacity, selecting a vessel designed around the process can help create a more efficient and flexible production system.

Fabdec is currently exhibiting at World Dairy Expo 2026 in Madison, Wisconsin, joining dairy producers, equipment manufacturers and industry specialists from across the world.

Running from 29 September to 2 October 2026, World Dairy Expo brings together the global dairy industry for four days of trade exhibits, education, networking and dairy cattle shows.

This year, Fabdec is showcasing a range of dairy cooling and farm equipment solutions, with a particular focus on technologies designed to improve milk cooling performance, energy efficiency and day-to-day operation on dairy farms.

Visitors to the Fabdec stand can find information on a number of our key dairy systems, including the DX-CO bulk milk tank, INSTA-KOOL falling film chiller, QUANTUS and MAGNUS plate coolers, SPIRA-KOOL tubular cooler, SPAR-HEAT heat recovery system and the FOOT-WASH Pro automatic hoof washing system.

Supporting Modern Dairy Farms

World Dairy Expo provides an important opportunity for Fabdec to meet dairy farmers, dealers and industry partners from across North America and further afield.

With dairy operations continuing to place greater emphasis on efficient cooling, energy recovery and reliable equipment, the event provides an ideal setting to discuss how Fabdec systems can be incorporated into both new and existing dairy installations.

From rapid milk cooling and pre-cooling through to heat recovery and automated hoof washing, Fabdec’s dairy range is designed around improving efficiency while providing robust equipment suitable for demanding farm environments.

Visit Fabdec at World Dairy Expo

The World Dairy Expo trade show continues until Friday, 2 October, at the Alliant Energy Center in Madison, Wisconsin.

If you’re attending the show, visit the Fabdec team to discuss your dairy cooling requirements and discover more about our milk cooling, pre-cooling and farm equipment solutions.

Unable to attend World Dairy Expo? Explore the full Fabdec Dairy Systems range online or contact our team to discuss your requirements.

The UK’s transition towards lower-carbon home heating continues to gather pace, with government funding now supporting a growing number of heat pump and energy-efficiency installations across the country.

The Warm Homes Plan, published in January 2026, sets out the government’s wider strategy for improving the energy performance of UK homes and accelerating the adoption of low-carbon technologies. Alongside existing support such as the Boiler Upgrade Scheme, this represents a significant opportunity for installers, contractors and housing providers delivering heat pump retrofit projects.

While much of the attention naturally falls on the heat pump itself, successful installations also depend on the wider system around it. For many properties, that includes an appropriately specified hot water cylinder.

Heat Pumps at the Centre of Home Heating Investment

Government support for heat pumps is now available through several routes.

The Warm Homes: Local Grant is being delivered through local authorities in England and can support energy-efficiency measures and low-carbon heating in eligible homes. This includes measures such as insulation, solar PV and air source heat pumps where suitable.

Separate funding is available through the Boiler Upgrade Scheme in England and Wales. Eligible property owners can currently receive £7,500 towards the installation of an air-to-water or ground source heat pump, while qualifying off-gas-grid properties replacing oil or LPG heating can receive £9,000 until 31 March 2027.

With increasing numbers of households expected to move away from traditional fossil-fuel heating systems, attention must also be given to how domestic hot water will be generated and stored.

Why Hot Water Storage Matters in a Heat Pump System

A heat pump operates differently from a conventional gas or oil boiler.

Rather than producing very high water temperatures over a short period, heat pumps generally operate most efficiently at lower flow temperatures. As a result, the design of the hot water system becomes particularly important.

In properties moving from a combi boiler, installing a heat pump can also mean introducing stored hot water where previously there may not have been a cylinder at all.

The cylinder therefore needs to be considered as part of the complete system rather than as a secondary component.

Factors such as cylinder capacity, heat exchanger performance, recovery requirements and available installation space all need to be considered when specifying a system.

Choosing a Hot Water Cylinder for a Heat Pump

Heat pump cylinders are designed to maximise heat transfer from lower-temperature primary water.

Compared with many conventional indirect cylinders, heat pump-compatible models typically require a greater heat-transfer area to efficiently transfer energy into the stored domestic hot water.

Correct specification can therefore have a significant influence on system performance.

Installers and contractors should consider:

• The required hot water storage capacity.
• Available heat exchanger surface area.
• Heat pump output and operating temperatures.
• Expected hot water demand.
• Cylinder recovery performance.
• Available installation space.
• Pipework and connection requirements.
• Whether single or twin-coil configurations are required.

Considering these factors at the design stage helps ensure the heat pump and hot water system operate together effectively.

Supporting Heat Pump Installations with EXCELSIOR WHP

The EXCELSIOR WHP range has been developed specifically for heat pump applications, providing dedicated hot water storage for systems operating with lower primary temperatures.

Manufactured by Fabdec in the UK, the range is available in a selection of capacities and configurations to support different residential and project requirements.

The WHP range incorporates heat exchangers designed for heat pump applications, with single and twin-coil options available across selected models. Larger models are also available with 28 mm connections where increased flow rates are required.

For installers, contractors and specifiers, this provides a purpose-designed alternative to attempting to adapt a conventional cylinder to a low-temperature heating system.

A Growing Opportunity for Installers and Retrofit Contractors

Warm Homes funding is already moving into delivery through local authorities across England.

Funding allocations extend across the country, including significant programmes in areas close to Fabdec’s manufacturing base. Cheshire East, for example, has received more than £8 million through the Warm Homes: Local Grant programme alongside Cheshire West and Chester and Warrington.

This funding, combined with continued support through the Boiler Upgrade Scheme and wider investment in residential decarbonisation, is expected to create continued demand throughout the heating and retrofit supply chain.

For contractors delivering these projects, reliable access to compatible heating equipment will be increasingly important.

This includes not only the heat pump, but the hot water storage, controls and associated equipment required to create a complete system.

UK-Manufactured Hot Water Storage for Retrofit Projects

As the UK increases investment in heat pump installations, manufacturers have an important role to play in ensuring installers and contractors have access to appropriately specified equipment.

EXCELSIOR manufactures stainless steel hot water cylinders at Fabdec Group’s UK manufacturing facility in Ellesmere, Shropshire, supplying installers, merchants and heating professionals across the UK and internationally.

The EXCELSIOR WHP range provides a dedicated solution for heat pump installations, from individual residential projects through to larger retrofit requirements.

For installers, contractors, housing providers or project teams planning heat pump installations, the Fabdec team can provide support with hot water cylinder selection and specification.

Planning a heat pump installation or retrofit programme?

Explore the EXCELSIOR WHP heat pump cylinder range or contact Fabdec to discuss your hot water storage requirements.

Hot water demand in industrial and commercial environments can be very different from that of a typical domestic property. Larger volumes, longer operating hours and periods of intense peak demand can quickly push conventional hot water systems beyond what they were designed to provide.

For facilities that require a dependable supply of stored hot water, an industrial hot water cylinder can offer the capacity, recovery performance and durability needed to support everyday operations.

But when does an application actually require an industrial system?

When Hot Water Demand Becomes Too High for a Domestic System

One of the clearest indicators is simply the volume of hot water being used.

Domestic cylinders are designed around the requirements of homes, where demand is relatively predictable and spread across a limited number of outlets. Commercial and industrial premises may need to supply multiple showers, wash stations, kitchens or pieces of equipment simultaneously.

At this point, both storage capacity and the ability to recover hot water quickly become increasingly important.

Industrial hot water cylinders are designed for these higher-demand applications, providing significantly greater stored volumes while allowing the system to be specified around the requirements of the site.

When Your Site Experiences Large Peaks in Demand

Average daily consumption does not always tell the full story.

A facility might use a manageable amount of hot water across an entire day but require a substantial proportion of it within a short period. Examples could include:

• Changing rooms where multiple showers are used at the end of a shift
• Hotels experiencing concentrated morning demand
• Commercial kitchens during busy service periods
• Manufacturing facilities carrying out scheduled cleaning or washdown
• Leisure centres with showers and changing facilities in continuous use

In these situations, sufficient stored hot water can help the system respond to sudden increases in demand without a noticeable reduction in availability.

When Hot Water Is Critical to Your Operation

In some environments, running out of hot water is more than an inconvenience.

Food production, manufacturing, healthcare, hospitality and other commercial facilities can depend on reliable hot water for cleaning, hygiene and everyday operation.

Where hot water forms part of a critical process, the system needs to be designed around both expected consumption and periods of maximum demand.

An appropriately sized industrial hot water cylinder provides a reserve of heated water that can be drawn from when required while the system continues to recover.

When You Need Faster Hot Water Recovery

Storage volume is only one part of specifying a commercial or industrial hot water system.

Recovery rate determines how quickly the water within the cylinder can be reheated after use. A large cylinder with insufficient heat input may still struggle to meet demand if significant quantities of hot water are repeatedly drawn from it.

When specifying a system, consideration should therefore be given to the heat source, heat exchanger performance, incoming water temperature and expected usage profile alongside the cylinder’s overall capacity.

Getting this balance right can be particularly important in facilities operating for long periods or experiencing repeated demand peaks throughout the day.

When Your Existing Hot Water System Is Regularly Struggling

Recurring hot water shortages can be an indication that the existing system is no longer suited to the application.

This can happen when a business expands, additional equipment is installed or more people begin using the facility.

Typical warning signs can include hot water running out during busy periods, long recovery times or operational schedules having to be planned around the availability of hot water.

Rather than simply increasing the cylinder size, the complete hot water requirement should be assessed. Capacity, recovery performance, heat source and distribution all contribute to the performance of the overall system.

Where Are Industrial Hot Water Cylinders Used?

Industrial and commercial hot water cylinders can be found across a broad range of applications, including:

• Manufacturing facilities
• Food and beverage production
• Hotels and hospitality
• Leisure centres and gyms
• Schools and universities
• Healthcare environments
• Commercial kitchens
• Agricultural facilities
• Marine and offshore applications
• Large commercial buildings

The exact specification will depend heavily on how, when and why hot water is required.

Choosing the Right Industrial Hot Water Cylinder

There is no single cylinder size that is suitable for every industrial application.

The correct system depends on factors including the required storage volume, peak demand, available heat source, required recovery time, operating pressure and available installation space.

EXCELSIOR industrial and commercial hot water cylinders are manufactured by Fabdec in stainless steel and are available in capacities from 500 to 3,400 litres, allowing systems to be specified for a wide range of high-demand applications.

Because Fabdec manufactures its vessels in-house, cylinders can also be configured around the requirements of individual projects where a standard specification is not suitable.

Need Help Specifying an Industrial Hot Water Cylinder?

If your existing hot water system is struggling to meet demand, or you are designing a new commercial or industrial installation, understanding the site’s actual usage requirements is an important first step.

The Fabdec team can help assess your application and identify an appropriate EXCELSIOR hot water solution based on required capacity, heat source and expected demand.

Contact Fabdec to discuss your industrial or commercial hot water requirements.