AI data centres are placing new demands on cooling systems.

As artificial intelligence workloads become larger and more power-intensive, servers and GPUs are producing greater amounts of heat. This heat must be removed continuously to protect performance, reliability and uptime.

For many high-density data centres, liquid cooling is becoming an important part of the solution. Instead of relying only on air to cool server rooms, liquid cooling allows heat to be captured closer to the source. Water or specialist cooling fluid can pass through the system, absorb heat from the equipment and carry it away through a controlled loop.

However, once that water has absorbed the heat, one important question remains.

Could that heat be reused before it is wasted?

Recovering heat from the cooling loop

In a liquid-cooled data centre, the cooling loop is designed to remove heat from IT equipment. Cool water enters the system, passes through the cooling circuit, absorbs heat from the servers and leaves warmer than it entered.

In many systems, that heat is then rejected through conventional cooling equipment.

However, there is another opportunity.

Before the heat is rejected, it could be transferred into a hot water or pre-heat system. This would allow the data centre to reuse some of the heat it has already created, rather than treating it only as waste.

This is where Fabdec Energy Blade technology could offer an interesting route forward.

Where the Energy Blade fits

The Fabdec Energy Blade has traditionally been used in water-source heat pump applications, often installed in suitable bodies of water such as lakes, rivers, canals or reservoirs.

In those applications, the Energy Blade provides stainless steel heat exchange surface area, allowing heat to transfer between the surrounding water and a connected thermal system.

But the principle does not need to be limited to open water.

At its core, the Energy Blade is a stainless steel heat exchange product. It is designed to allow heat to move from one liquid environment into another system.

For data centre heat recovery, Energy Blades could potentially be adapted as a heat transfer stage within a closed liquid cooling loop.

In this version, the Energy Blade would not sit in a canal or river. It would form part of the controlled cooling circuit. Water would pass through the data centre cooling system, pick up heat from the servers, then continue through the Energy Blade section before returning to the cooling loop.

The Energy Blade would help extract heat from that warmed water and make it available for hot water generation.

Using recovered heat for hot water

Data centres need cooling, but they can also have hot water demand.

Recovered heat from the liquid cooling loop could potentially support:

• washrooms
• staff welfare areas
• kitchens
• offices
• cleaning requirements
• plant room services
• pre-heating for commercial hot water systems

The recovered heat may not always be hot enough to produce final-use hot water by itself. That depends on the temperature of the cooling loop and the requirements of the hot water system.

However, even pre-heating can be valuable.

If incoming cold water is raised in temperature before it reaches the main water heating system, the primary heater has less work to do. A boiler, heat pump or immersion heater can then provide the remaining temperature lift where required.

This means the data centre can reduce wasted heat and make better use of the energy already produced by its IT equipment.

Why the closed-loop approach matters

The key advantage of this concept is that it keeps the system controlled.

The water used in the cooling loop can remain within a closed circuit. This helps maintain water quality, flow control and system reliability.

The Energy Blade would act as a heat transfer section within that loop, rather than relying on an open external water source. This could make the concept more relevant to data centres that do not have access to a lake, river, canal or reservoir.

It also changes the way Energy Blade technology is positioned.

Instead of being seen only as a water-source heat pump product, it can be understood as a stainless steel heat exchange solution that could be adapted for controlled liquid-based thermal systems.

Designed around the application

Data centre cooling is mission-critical. Any heat recovery system must be designed so that it supports the cooling strategy without putting IT equipment at risk.

Important design questions would include:

• What temperature does the cooling loop operate at?
• What flow rate is required?
• How much heat can be recovered?
• What pressure is the system operating at?
• What fluid is used in the cooling loop?
• What hot water demand exists on site?
• Is the recovered heat used directly or as a pre-heat stage?
• Is a heat pump required to raise the temperature?
• What backup heating is needed?
• What redundancy is required?
• How will the system be isolated for maintenance?

These questions are important because every data centre is different. The correct solution would need to be designed around the thermal load, cooling infrastructure and site hot water demand.

Fabdec’s role would be to support that design with stainless steel heat exchange technology and bespoke thermal manufacturing experience.

Turning server heat into useful energy

The main proposition is simple.

The data centre already creates heat. The liquid cooling system already captures it. Energy Blade technology could help recover some of that heat before it is rejected.

This would allow a data centre to:

• reduce wasted heat
• support hot water generation
• reduce demand on primary water heating systems
• improve building services efficiency
• make better use of existing energy
• support lower-carbon site operation
• connect cooling infrastructure with hot water demand

The Energy Blade is not replacing the data centre cooling system. It is adding a heat recovery opportunity within the loop.

From liquid cooling to hot water

AI data centres are producing large amounts of heat. Liquid cooling offers an efficient way to capture that heat, but the next step is deciding how that heat is used.

Energy Blade technology could provide a practical route for recovering heat from a closed liquid cooling loop and transferring it into hot water generation.

For data centres, this creates a simple opportunity:

Cool the servers. Capture the heat. Reuse it for hot water.

As AI infrastructure continues to grow, data centres will need to think beyond cooling alone. The most efficient sites will also consider how recovered heat can be turned into a useful resource.

Discuss data centre heat recovery with Fabdec

Fabdec manufactures stainless steel Energy Blades and thermal products for heat recovery, water heating and bespoke system integration.

If you are designing a data centre, liquid cooling system, energy centre or commercial heat recovery project, Fabdec can discuss how Energy Blade technology could be adapted to support closed-loop thermal recovery and hot water generation.

Contact Liam Bowen to discuss Energy Blade heat recovery for data centre liquid cooling systems.

A process vessel is more than a stainless steel tank. In many production environments, it plays a direct role in how a product is stored, mixed, heated, cooled or prepared before moving to the next stage of manufacture.

Because of this, process vessel design should always be based on the product, the process and the operating environment. A vessel that works well for one application may not be suitable for another, even if the capacity appears to be the same.

From food and beverage production to chemical and pharmaceutical processing, the right vessel design can improve performance, support hygiene standards and help create a more reliable production process.

What is a process vessel?

A process vessel is a stainless steel vessel used to hold, mix, heat, cool or process a product during manufacture. Depending on the application, it may be used as a buffer tank, mixing vessel, jacketed vessel, pressure vessel or specialist production vessel.

Process vessels are used across a wide range of industries, including food, beverage, dairy, chemical and pharmaceutical manufacturing. They can be designed for simple storage, controlled temperature processing, agitation, product transfer or integration into a wider production line.

The design of the vessel depends on what the product needs to do inside it. This includes how the product behaves, how it needs to be handled and what conditions are required during processing.

1. Product and process requirements

The first consideration in process vessel design is the product itself. Before choosing the vessel size, fittings or heating method, it is important to understand how the product behaves during production.

Some products are thin and free-flowing. Others are thicker, more viscous or more sensitive to movement. A sauce, syrup, cream, chemical mixture or pharmaceutical product may each require a different approach to handling, mixing and temperature control.

Key questions include:

• Does the product need to be heated or cooled?
• Does it need to be mixed or gently agitated?
• Is the product sensitive to shear or damage?
• Does it need to be held at a specific temperature?
• Will the vessel be used for storage, processing or both?
• Does the product require hygienic or specialist handling?

Answering these questions early helps ensure the vessel is designed around the real process, rather than simply selected by capacity.

2. Material selection and hygienic design

Stainless steel is commonly used for process vessels because it is strong, durable, corrosion resistant and suitable for hygienic applications. For food, beverage, dairy and pharmaceutical environments, stainless steel also supports cleanability and long-term product safety.

However, the material alone is not the only consideration. The vessel design must also support hygienic operation. This includes the quality of the internal finish, the design of welds, the positioning of outlets and the ability to clean the vessel effectively.

Poorly designed internal areas can create places where product may collect. This can make cleaning more difficult and increase the risk of contamination or production downtime.

A well-designed process vessel should consider:

• Internal surface finish
• Weld quality
• Drainability
• Cleaning access
• Outlet positioning
• Hygienic fittings
• Suitability for CIP where required

For demanding production environments, these details can be just as important as the vessel capacity itself.

3. Capacity, footprint and installation space

Capacity is usually one of the first details discussed when specifying a process vessel. However, volume is only part of the design process.

The vessel also needs to fit the available space on site. This can include height restrictions, access through doors, pipework positions, floor layout, service access and the wider production flow around the vessel.

A standard vessel may not always suit these requirements. For example, a site may need a lower vessel due to ceiling height, a narrower vessel because of access restrictions, or a specific outlet position to connect with existing pipework.

Bespoke process vessel design allows these details to be considered from the start. This can help reduce installation issues and create a vessel that works more effectively within the production environment.

The main layout considerations include:

• Vessel height and diameter
• Working capacity
• Access around the vessel
• Leg or frame design
• Outlet and inlet positions
• Pipework connections
• Installation access
• Cleaning and maintenance space

A process vessel should be designed for how it will be used on site, not just how it appears on a drawing.

4. Heating and cooling requirements

Many process vessels need some form of temperature control. This may involve heating, cooling or maintaining a product at a specific temperature during processing.

The right solution depends on the product, the required temperature range and how quickly the temperature needs to change. Some applications may require gentle heating, while others need faster heat transfer or controlled cooling.

Common options include jacketed vessels, internal coils and immersion heaters. Each method has its own benefits depending on the process and the product being handled.

Heating and cooling design can affect:

• Processing time
• Product consistency
• Energy efficiency
• Temperature accuracy
• Product quality
• Cleaning requirements

For applications where temperature control is critical, this part of the vessel design should be considered early. Retrofitting or changing thermal transfer surfaces later can be difficult, costly and disruptive.

5. Agitation and mixing

Agitation is another important part of process vessel design. The type, speed and position of the agitator can all affect product movement and final consistency.

Some products need continuous mixing to prevent separation. Others need gentle agitation to avoid damaging the product. Higher viscosity products may require a different agitator design compared with thinner liquids.

The vessel shape also plays a role. Diameter, base design, baffles and outlet position can all influence how the product moves inside the vessel.

Good agitation design helps support:

• Consistent product quality
• Even heating or cooling
• Reduced settling or separation
• Better batch repeatability
• Improved process control

The agitator should not be treated as an add-on. It should be considered as part of the overall vessel design.

6. Cleaning, access and maintenance

Cleaning and maintenance are essential in most process environments. A vessel may perform well during production, but if it is difficult to clean or maintain, it can create downtime and operational issues.

For hygienic applications, cleanability should be considered at the design stage. This includes access points, manways, spray balls, CIP connections, drainability and the ability to inspect internal surfaces where required.

Maintenance access is also important. Components such as agitators, seals, valves and fittings should be positioned so they can be serviced without unnecessary disruption.

A good vessel design should help reduce avoidable downtime by making cleaning, inspection and maintenance as straightforward as possible.

Key considerations include:

• Access hatches or manways
• CIP compatibility
• Drain points
• Removable components
• Valve access
• Agitator maintenance
• Internal inspection
• Safe working access

The easier a vessel is to clean and maintain, the more practical it becomes in day-to-day production.

7. Fabrication quality and long-term reliability

The quality of fabrication has a major impact on the long-term reliability of a process vessel. Stainless steel vessels are often expected to operate for many years, so the design and build quality need to support long service life.

Weld quality, material selection, finishing, testing and inspection all contribute to the final performance of the vessel. Poor fabrication can lead to hygiene issues, mechanical problems, corrosion risks or premature failure.

For vessels used in demanding production environments, quality should be built into every stage of manufacture. This includes design review, fabrication control, welding standards, pressure requirements where applicable and final inspection before delivery.

A reliable process vessel should not only meet the immediate production need. It should also be robust enough to support future production demands.

Why choose a bespoke process vessel?

A bespoke process vessel gives manufacturers greater control over how the vessel is designed, built and integrated into their production process.

Rather than adapting the process to suit a standard tank, a bespoke vessel can be designed around the product, site layout, production flow and operational requirements.

This can be especially valuable when dealing with unusual product characteristics, restricted installation spaces, specialist heating or cooling needs, hygiene requirements or specific pipework connections.

Bespoke design can help with:

• Non-standard capacities
• Restricted access or height limits
• Specialist agitation
• Heating and cooling requirements
• Hygienic design
• Custom fittings
• Skid-mounted systems
• Integration with existing equipment
• Future production flexibility

For many manufacturers, the value of a bespoke vessel comes from reducing compromise. The vessel is designed to work with the process from the beginning.

Process vessel design from BRITANX Process

BRITANX Process designs and manufactures bespoke stainless steel process vessels for a wide range of industries, including food, beverage, dairy, chemical and pharmaceutical manufacturing.

Our vessels can be designed around the specific requirements of the product and process, including heating, cooling, agitation, pressure requirements, hygiene considerations and site restrictions.

With in-house design and stainless steel fabrication expertise, BRITANX Process can support projects from initial specification through to completed manufacture. This allows key design details to be considered early, helping create a vessel that is practical, reliable and suited to its operating environment.

Whether you need a mixing vessel, jacketed vessel, buffer tank, pressure vessel or a bespoke stainless steel process solution, our team can help develop a design that fits your production requirements.

Speak to BRITANX Process

Choosing the right process vessel starts with understanding the product, the process and the production environment.

If you are planning a new process vessel or reviewing an existing production setup, BRITANX Process can help you explore the right design for your application.

Contact BRITANX Process to discuss your next stainless steel process vessel project.

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Hot water is essential on every dairy farm. From plant washing to tank cleaning and general hygiene, reliable hot water plays a direct role in daily operation. However, producing that hot water can also create a significant and ongoing energy cost.

At the same time, dairy farms are already removing large amounts of heat during the milk cooling process. In many systems, this heat is rejected through refrigeration and lost to the surrounding environment. Heat recovery changes that. Instead of allowing useful heat to go to waste, it can be captured and used to pre-heat water.

Fabdec’s SPAR-HEAT system is designed to recover heat from the refrigeration process and transfer it into a dedicated stainless steel hot water vessel. This reduces the amount of energy required to heat water to the final required temperature, helping farms lower running costs while making better use of energy already present in the system.

Turning Recovered Heat into Real Value

To show the potential value of heat recovery, Fabdec has calculated example annual recovered values across the SPAR-HEAT range. These figures are based on heating the full vessel volume once per day, 365 days per year, using a 50°C temperature lift and an energy cost of £0.25 per kWh.

For example, a 500 litre SPAR-HEAT vessel requires approximately 29.0 kWh to heat by 50°C. At £0.25 per kWh, that represents a potential recovered value of £2,648.78 per year.

Larger vessels offer even greater potential. A 1,125 litre SPAR-HEAT vessel represents approximately 65.3 kWh of recoverable heat per full daily heat cycle, giving an example annual recovered value of £5,959.77. At the top of the standard range, a 3,000 litre vessel represents approximately 174.2 kWh, with an example annual recovered value of £15,892.71.

These figures are designed to give farms a practical indication of the energy value that can be recovered. Actual savings will depend on refrigeration duty, system runtime, hot water usage, energy costs and site conditions.

Why Milk Cooling Creates a Heat Recovery Opportunity

Milk cooling and water heating are two of the most energy-intensive processes on many dairy farms. Fresh milk must be cooled quickly and reliably, while hot water must be available for cleaning and hygiene routines.

Normally, the refrigeration system removes heat from the milk and rejects it through the condenser. With SPAR-HEAT, this heat can be transferred into water before it reaches the main water heating system. As a result, the water heater has less work to do because the incoming water has already been pre-heated.

This does not remove the need for final water heating where higher temperatures are required. However, it can significantly reduce the energy needed to reach those temperatures.

Built for Dairy Heat Recovery

SPAR-HEAT is available in capacities from 150 litres to 3,000 litres, allowing the system to be matched to different farm sizes and hot water requirements. Each vessel is manufactured from stainless steel and can be configured for new installations or retrofit projects.

The system uses coil heat exchangers to transfer recovered heat into the water. Depending on vessel size, SPAR-HEAT models are available with one or multiple coil heat exchangers to support the required recovery capacity.

Because the system is designed around the existing refrigeration process, it helps farms make better use of energy that is already being generated during milk cooling. This makes SPAR-HEAT a practical choice for farms looking to improve efficiency without adding unnecessary complexity.

A Practical Way to Reduce Dairy Energy Costs

Energy prices have made running costs a greater priority for dairy businesses. While every farm is different, heat recovery offers a straightforward principle: recover useful heat from milk cooling and use it to reduce water heating demand.

For farms with consistent milk cooling and hot water requirements, the recovered value can build up quickly over the year. Even where daily usage varies, the opportunity remains clear. Heat that would otherwise be rejected can instead contribute to the farm’s hot water supply.

By combining stainless steel vessel manufacturing with dairy system knowledge, Fabdec can help farms identify the right SPAR-HEAT size for their operation and estimate the potential recovered value based on real usage.

Calculate Your Potential SPAR-HEAT Saving

The example values shown above are based on standard assumptions, including a 50°C temperature lift and an energy cost of £0.25 per kWh. For a more accurate estimate, farms should consider daily milk volume, refrigeration runtime, hot water demand and current energy costs.

To find out how much heat your dairy farm could recover, speak to Fabdec about SPAR-HEAT dairy heat recovery systems.

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