Pictured alongside the first of Fabdec’s newly updated INSTA-KOOL Falling Film Chiller are members of the company’s engineering, design and senior management teams, ahead of the unit’s journey to World Dairy Expo in Madison, Wisconsin at the end of September.

The team includes four Fabdec engineers, a design engineer, the General Manager and the Managing Director, representing the different areas of the business involved in developing and manufacturing the latest version of the INSTA-KOOL.

The completed unit is an 800-litre, 12-plate INSTA-KOOL and is the first to feature a new design that will now be introduced across the range.

Introducing the New INSTA-KOOL Design

The key update is the addition of a top access drawer, designed to make cleaning and routine maintenance easier.

The drawer provides direct access to the reservoir and distribution area above the plates. Over time, dirt or debris can build up within this section of the chiller. The new design allows the area to be accessed more easily, making it simpler to remove any accumulation during cleaning.

This helps support improved hygiene, easier servicing and more straightforward long-term maintenance.

To accommodate the new access system, the outer shape of the INSTA-KOOL has also been updated, giving the latest model its revised appearance.

The top drawer will now become a standard feature across the INSTA-KOOL range moving forward.

Proven Falling Film Cooling Technology

While the external design has changed, the cooling principle behind the INSTA-KOOL remains the same.

Water is distributed across the stainless steel cooling plates inside the unit, where it flows over their surface as a thin film. As the water passes across the chilled plates, its temperature is reduced before it is circulated onwards to a plate cooler.

Within the plate cooler, the chilled water and warm milk flow through separate channels alongside one another. This allows heat to transfer from the milk into the colder water without the two liquids coming into contact.

The cooled water can then continue through the system as part of the pre-cooling circuit, helping reduce the milk temperature before it reaches the bulk milk tank.

By removing heat from the milk before storage, the system can reduce the refrigeration demand placed on the bulk tank and support more efficient milk cooling.

Heading to World Dairy Expo

Following completion at Fabdec’s Ellesmere manufacturing facility, the first updated INSTA-KOOL is now preparing to travel to Madison, Wisconsin, for World Dairy Expo at the end of September.

The event provides an opportunity to showcase Fabdec dairy cooling technology to the North American market, while this particular unit also marks the introduction of the latest development in the INSTA-KOOL range.

With its new top access drawer now becoming standard across future models, the 800-litre, 12-plate chiller represents the first of Fabdec’s updated generation of INSTA-KOOL Falling Film Chillers.

To learn more about the INSTA-KOOL Falling Film Chiller and Fabdec’s wider range of dairy cooling equipment, contact the Fabdec Dairy Systems team.

Fabdec has expanded its in-house manufacturing capabilities with the addition of a new laser engraving system at our Ellesmere factory.

The new equipment allows us to produce detailed identification plates for our process vessels directly on site. These plates can include essential vessel information such as serial numbers, design temperatures, pressure data, material specifications, manufacturing dates and certification details.

Importantly, the system is also capable of producing colour laser markings, giving Fabdec greater flexibility over both the technical information and presentation of each finished vessel.

Greater Control Over the Finished Product

Every process vessel manufactured by Fabdec is built around the requirements of the individual application. That means identification plates can vary significantly depending on the vessel specification, operating conditions and applicable standards.

Bringing laser engraving in-house gives our manufacturing team greater control over this final stage of production.

Rather than relying on externally produced plates, vessel information can now be engraved as part of the manufacturing process. This helps improve consistency, flexibility and turnaround times, particularly on bespoke projects.

Clear and Permanent Vessel Identification

Identification plates provide operators, engineers and maintenance teams with important information throughout the working life of a vessel.

Laser engraving creates a permanent, precise marking directly onto the plate surface. This makes it well suited to industrial environments where durability and long-term legibility are important.

The system can reproduce detailed technical data alongside company branding, certification information and colour elements, allowing the plate to become a more integrated part of the finished vessel rather than simply an attached label.

Supporting Vessel Traceability

Traceability remains an important part of process vessel manufacture.

Individual serial numbers, material information and manufacturing data help connect the physical vessel with its associated documentation and production records.

Producing these plates internally gives Fabdec another level of control over how this information is applied to each completed vessel.

For customers, it provides clear identification of the equipment from the point of manufacture and throughout its service life.

Continued Investment at Fabdec

The new laser engraving system is another example of Fabdec investing in modern manufacturing technology at our UK facility.

While engraving represents only one part of the overall production process, bringing more capabilities in-house helps us maintain control over quality from initial fabrication through to the final details of the finished product.

Fabdec continues to invest in equipment, technology and manufacturing processes that support the production of bespoke stainless steel vessels for customers across a wide range of industries.

From fabrication and heat transfer technology through to testing, identification and final preparation, our aim is to maintain as much control over the finished product as possible.

Shipping a 16,000-litre stainless steel dairy tank across the Atlantic requires more than simply finding a large enough container.

For a recent North American order, Fabdec prepared and shipped two DX-CO container dairy tanks with capacities of 12,000 and 16,000 litres. Alongside the tanks, the shipment also included QUANTUS plate coolers and FOOT-WASH Pro cow footbath systems, creating a comprehensive package of Fabdec dairy equipment ready for installation on arrival.

The shipment provides a good example of why the DX-CO was developed specifically with international transport in mind.

Designed Around Containerised Export

Large dairy tanks can present significant logistical challenges when they need to travel internationally.

The shape and configuration of the DX-CO help overcome these challenges. Each vessel can be positioned on its side within the container, while the pipework is located at the rear of the tank to help maximise the available space.

For this North American shipment, both the 12,000 and 16,000-litre vessels were a snug fit in terms of their width and height. However, careful use of the remaining container space meant there was still room to ship additional Fabdec equipment alongside them.

This included plate coolers and FOOT-WASH Pro systems supplied as part of the same customer order.

Preparing the Tanks for Their Journey

Before leaving Fabdec, each DX-CO undergoes a final inspection.

Once the inspection is complete, our team professionally wraps and protects the vessel. This preparation helps protect the stainless steel surfaces throughout handling and transportation, ensuring the equipment arrives in excellent condition.

For this shipment, external lifting specialists then assisted with loading the tanks.

The wrapped vessels were carefully craned from above and lowered into open-top shipping containers. With only limited clearance around the vessels, accurate positioning was essential.

Secured for International Transport

Once positioned inside the container, the equipment must remain secure throughout its journey.

The tanks were stabilised using protective air bags and ratchet straps. These help prevent unwanted movement while also protecting the vessel and surrounding equipment during transport.

The result is a tightly packed container containing not only a substantial milk cooling tank, but also additional equipment required for the customer’s dairy installation.

Ready for Installation on Arrival

Container-friendly design also helps simplify what happens at the other end of the journey.

Once the equipment reaches its destination in North America and is unloaded, the DX-CO is ready to move into the installation stage. This helps customers source major pieces of their dairy cooling and farm equipment from one manufacturer and have them transported together.

As Fabdec’s international dairy business continues to grow, shipments of this type are becoming increasingly common.

Designing equipment with transportation in mind allows us to supply large-capacity dairy systems to customers much further afield without compromising the quality or functionality of the finished product.

Dairy Equipment Built for International Projects

Fabdec manufactures dairy cooling, storage, pre-cooling and farm equipment from our UK manufacturing facility, supplying customers across international markets.

The DX-CO container tank is one example of how product design can help make large-scale dairy equipment more practical to transport internationally.

Available in a range of capacities, DX-CO tanks combine stainless steel construction, milk cooling capability and a container-conscious configuration for dairy projects where export logistics matter.

Planning an international dairy project?

Speak to Fabdec about milk cooling tanks, pre-cooling equipment and dairy farm systems for projects in the UK and overseas.

Fabdec has renewed its ISO 9001 certification, effective from 29 July 2026.

The renewal reflects our continued commitment to controlled processes, consistent manufacturing standards and ongoing improvement across the business.

For customers, ISO 9001 certification provides independent assurance that quality is managed through a structured and regularly reviewed system.

What ISO 9001 Means for Customers

ISO 9001 is an internationally recognised quality management standard. It focuses on how an organisation controls its processes, responds to issues and maintains consistent standards.

For customers purchasing stainless steel equipment, quality assurance applies throughout the project lifecycle. It begins with the initial enquiry and continues through design, material control, manufacture, inspection and delivery.

This helps ensure that customer requirements are clearly understood, documented and followed throughout production.

Quality Across the Manufacturing Process

Many Fabdec products are designed around specific customer requirements. Bespoke manufacturing therefore depends on accurate communication, controlled documentation and consistent production methods.

Our quality management system supports the control of drawings, materials, production records and inspection procedures.

Depending on the project, completed equipment may be checked for dimensional accuracy, surface finish, pressure integrity, connection positions and compliance with the agreed design.

These processes help reduce the risk of errors and provide customers with greater confidence in the finished product.

Supporting Continuous Improvement

ISO 9001 also requires organisations to identify problems, investigate their causes and take corrective action.

Customer feedback, internal reviews and production findings can all contribute to improvements in the way products are designed, manufactured and delivered.

This supports greater consistency across Fabdec’s stainless steel process vessels, dairy equipment and water heating solutions.

Continued Commitment to Quality

Renewing our ISO 9001 certification confirms that Fabdec’s quality management system continues to meet the requirements of the standard.

More importantly, it reinforces our ongoing commitment to reliable processes, consistent workmanship and customer satisfaction.

Whether you require a standard product or a fully bespoke stainless steel solution, our team can support your project from initial specification through to manufacture and delivery.

Contact Fabdec to discuss your requirements.

Marine calorifiers and industrial water heaters perform the same basic function. Both store and heat water for use across a building, facility or vessel.

However, a marine installation introduces a different set of engineering constraints.

Space is often limited. Access routes can be restrictive. Equipment must remain secure while the vessel moves. Connections may also need to suit an established onboard services layout.

As a result, a standard industrial water heater cannot always be transferred directly into a marine application.

Restricted space and installation access

Capacity is only one part of marine water heater specification.

Two cylinders can hold the same volume while having very different proportions. One may be tall and narrow, while another may be shorter with a larger diameter.

This matters because a marine calorifier may need to pass through:

• Restricted access hatches
• Narrow corridors
• Machinery-space doorways
• Existing pipework
• Areas with limited headroom
• Compartments containing fixed equipment

The route into the vessel can therefore be just as important as the final installation space.

Specifiers should confirm hatch sizes, doorway widths, turning space and lifting restrictions before approving the cylinder dimensions.

Where standard proportions will not work, a bespoke marine calorifier can provide the required capacity within a more suitable height and diameter.

Mounting and vessel movement

An industrial water heater normally stands vertically on a stable plant-room floor.

A marine calorifier operates in a moving environment. Its mounting arrangement must account for vibration, vessel movement and the available fixing points.

Depending on the application, this may require:

• A welded base plate
• Purpose-designed mounting brackets
• Additional fixing points
• Reinforced supports
• Horizontal installation
• A non-standard support arrangement

The intended orientation must be established before manufacture.

Immersion heaters, internal coils and connections must all be positioned to suit the final installation. A cylinder designed for vertical use should not simply be installed horizontally without confirming that its internal arrangement is suitable.

Custom connections and service access

Industrial water heaters often use established connection positions because the surrounding pipework can be routed to suit the cylinder.

Marine projects frequently work the other way around.

The calorifier may need to fit around:

• Existing pipe routes
• Bulkheads
• Machinery
• Electrical equipment
• Maintenance zones
• Restricted side access

Custom connection positions can reduce pipework changes and simplify installation.

These may include non-standard positions for:

• Cold-water inlets
• Hot-water outlets
• Primary coil connections
• Secondary returns
• Immersion heaters
• Temperature sensors
• Drain points
• Safety equipment

Top-mounted fittings may also be useful where access around the sides of the cylinder is limited.

Maintenance clearance should be considered at the same stage. It is not enough for the calorifier to fit into the space. Engineers must also be able to remove immersion heaters, inspect controls and access valves throughout the vessel’s service life.

What should marine specifiers provide?

The initial specification should include:

• Required capacity
• Maximum working pressure
• Design temperature
• Intended orientation
• Maximum height and diameter
• Installation access dimensions
• Mounting requirements
• Heat-source temperature and flow
• Recovery requirements
• Immersion heater requirements
• Connection sizes and positions
• Relevant project requirements

For replacement projects, drawings and photographs of the existing unit and surrounding space can also help identify potential constraints.

Bespoke marine water heating from EXCELSIOR

EXCELSIOR manufactures stainless steel marine water heaters for commercial and specialist applications.

Marine units can be designed around restricted installation spaces, onboard heat sources and project-specific connection requirements.

Available options include:

• Capacities from 50 to 3,000 litres
• Bespoke height and diameter combinations
• Custom connection positions
• Direct and indirect heating
• Application-specific internal coils
• Base plates for secure installation
• Optional top-mounted fittings
• Horizontal and vertical configurations
• Stainless steel construction

A marine calorifier should not be selected by capacity alone.

The correct unit must fit into the vessel, connect to the available services and deliver the required hot water performance. It must also remain secure and accessible throughout its working life.

Contact the EXCELSIOR team to discuss a new marine water heating project or the replacement of an existing marine calorifier.

Fabdec has manufactured a set of prototype pharmaceutical vessels designed to help a skincare manufacturer refine a new cream production process.

The project includes two 30-litre atmospheric vessels, each manufactured in separate upper and lower sections. This modular construction allows the vessel sections to be assembled, separated and reconfigured during process trials.

Alongside the primary vessel assemblies, two additional lower sections were produced. These give the customer the ability to compare both conical and dished-end configurations before selecting the most suitable design for future production equipment.

Comparing Vessel Geometries

The shape of a vessel’s lower section can influence product discharge, mixing behaviour, cleaning and the amount of material retained after processing. These considerations are particularly important when handling creams and other viscous skincare products.

Rather than committing immediately to a larger production vessel, the customer can use the 30-litre prototypes to test each bottom geometry under realistic process conditions.

The trials will help determine which configuration provides the best results for:

• Product movement and mixing
• Complete and controlled discharge
• Cleaning between batches
• Minimising residual product
• Supporting the intended manufacturing process

Once testing is complete, the preferred design can be incorporated into additional vessels manufactured for the customer’s wider production requirements.

Manufactured in Grade 316 Stainless Steel

All product-contact sections have been manufactured from grade 316 stainless steel. This material provides strong corrosion resistance while offering a smooth, hygienic surface suitable for processing creams, cosmetics and other sensitive products.

Each vessel has a nominal capacity of 30 litres and is designed for atmospheric operation. The compact scale makes the equipment suitable for prototype development, formulation testing and small trial batches.

The removable sections are secured using hygienic clamps, allowing the vessel configuration to be changed without manufacturing an entirely separate test unit for each geometry.

Supporting Process Development

Prototype vessels give manufacturers the opportunity to validate a process before investing in full-scale equipment. Mixing performance, discharge behaviour and cleaning requirements can all be assessed using the intended product rather than relying solely on theoretical calculations.

For this project, the interchangeable conical and dished lower sections provide a direct comparison between two potential vessel designs. The customer can gather practical data from each arrangement and make an informed decision before ordering further units.

This approach reduces the risk of selecting an unsuitable geometry and ensures that future vessels are based on a proven process.

Bespoke Pharmaceutical and Cosmetic Vessels

Fabdec manufactures stainless steel process vessels for pharmaceutical, cosmetic and other hygienic applications. From small prototype vessels to full production equipment, each system can be developed around the customer’s product, process and installation requirements.

Developing a new cosmetic or pharmaceutical process? Contact Fabdec to discuss a prototype or production vessel designed around your application.

When a power outage hits a working dairy farm, every minute matters. At Brookside Farm, a major electrical failure left essential cooling equipment out of action, creating an urgent situation that needed a fast and experienced response.

Cookes was called to site late at night after the initial fault was traced to a compressor failure, which caused a wider electrical issue across the farm’s cooling system. The issue was diagnosed as a phase-to-neutral failure, leading to a significant outage. When power was re-engaged, the failure resulted in further damage to key control components, including the GALA-KOOL Pro board for the silo, an ACDC transformer, and a level sensor relay.

With milk cooling affected and the farm needing the system brought back online as quickly as possible, the Cookes team worked through the night to trace the fault, replace damaged components, and restore cooling function.

Working Through the Night to Restore Cooling

The emergency call-out began at around 11pm, with the Cookes team remaining on site until approximately 4am. During this time, the engineers carried out a full fault-finding process to identify what had failed, what had been damaged by the outage, and what was required to safely restore the system.

Because dairy cooling systems rely on both refrigeration and control equipment working together, the issue was not limited to one component. The team had to work through the electrical damage step by step, restoring the control circuit and ensuring the silo could return to normal operation.

After several hours of work, cooling function was successfully restored, helping Brookside Farm return to operation and protecting the milk held on site.

Follow-Up Support the Next Day

The Cookes team returned to Brookside Farm the following day to complete the next stage of the repair. This included reprogramming the GALA-KOOL Pro board and checking that the system was operating as required after the emergency restoration work.

This follow-up visit was an important part of the service response. While the overnight work restored function, the return visit allowed the team to fine-tune the control system and ensure the equipment was properly set up for ongoing use.

Why Emergency Dairy Support Matters

Power failures and cooling faults can create serious pressure for dairy farms. When cooling equipment stops working, farms need more than just parts. They need engineers who understand dairy systems, control equipment, refrigeration, and the urgency of keeping milk at the correct temperature.

Cookes provides service support for dairy farms across the region, including emergency call-outs, fault diagnosis, cooling system repairs, and follow-up maintenance. The Brookside Farm call-out shows the value of having experienced engineers available when unexpected failures happen outside normal working hours.

From the initial late-night call to the return visit the next day, the priority was clear: restore cooling, support the farm, and get the system back under control.

Reliable Support for Dairy Cooling Systems

Unexpected faults can happen at any time, especially where electrical, refrigeration, and control systems work together. With the right support, farms can reduce downtime and protect critical cooling performance.

Cookes continues to support dairy farms with responsive service, practical fault-finding, and experienced engineering support when it matters most.

Need Support With Your Dairy Cooling System?

Speak to Cookes today to arrange dairy cooling support or discuss your servicing needs.