Author: CASSMAN Publish Time: 2025-09-05 Origin: CASSMAN BEER BREWING EQUIPMENT
Project Title: Delivering a Customised 600L Fermentation Tank to Seamlessly Integrate into an Existing UK Brewery
Client: "Oak & Iron Brewing," a popular and established craft brewery in Manchester, UK, known for its traditional cask ales and a growing range of modern craft beers.
Location: Manchester, United Kingdom
In the competitive and dynamic UK craft beer scene, flexibility is key to survival and growth. Manchester's "Oak & Iron Brewing" had built a strong reputation. Their core range of ales, produced in their 1200L (approx. 10BBL) system, was a local favourite. However, they faced a common problem of success: their most popular hazy IPA was selling out faster than they could brew it. Dedicating a full 1200L fermenter to this single beer was inefficient, and it left no room for the experimental, small-batch beers their brewers were eager to create. They were "capacity-locked," needing to expand not just in size, but in flexibility.
For an existing, operational brewery, adding a new fermentation tank is not as simple as just buying one off the shelf. The integration must be flawless to avoid disrupting their established workflow.
Capacity Bottleneck: Their star beer, a New England IPA, was constantly sold out. They needed to increase its production without committing to another large 1200L tank, which would be too much capacity for one beer and too great an investment.
Lack of Flexibility for Innovation: Their large fermenters were always occupied with their core range. This left no space for the brewers to develop new recipes, seasonal specials, or small-batch sours, stifling creativity and market responsiveness.
Seamless Physical and Functional Integration: The new tank had to be a perfect fit. It needed to match the existing tanks' height, footprint, and, most importantly, have identical port configurations (glycol inlets/outlets, sample port, racking arm) to work with their current pipework and procedures.
Uncompromising Hygiene and Quality: For a brewery looking to experiment with different yeast strains and potentially souring bacteria, the internal finish of the tank was critical. Any imperfection could lead to cross-contamination and ruin batches.
CASSMAN provided not just a product, but a bespoke solution: a single 600L Jacketed Conical Fermenter, engineered to be a perfect "twin" to their existing setup, only smaller.
Key Features of the Fermenter:
"Mirror-Finish" Internal Polishing (Ra < 0.4μm): The tank's interior was polished to an exceptionally smooth, mirror-like surface. This ultra-low-porosity finish is far superior to standard finishes, making it extremely easy to clean and sanitize, drastically reducing the risk of microbial contamination—a critical feature for the client's innovation goals.
Customised Port Configuration: Before production, we obtained the exact specifications and photos of the client's existing tanks. We then manufactured the new 600L tank with glycol ports, sample valve, thermowell, and racking arm placed at the exact same heights and orientations, ensuring a true "plug-and-play" installation.
High-Efficiency Dimple Jacket: The fermenter was fitted with a high-efficiency glycol jacket offering extensive cooling coverage. This provided precise temperature control, enabling rapid crash-cooling for faster tank turnover and the ability to hold steady, specific temperatures for lager or ale fermentation.
"Door-to-Door" Logistics & UKCA Compliance: We managed the entire logistics process, from secure crating at our factory to handling customs clearance in the UK and final delivery to their brewery door. The tank was certified to meet UKCA standards, ensuring full compliance with local regulations.
Our process was defined by meticulous attention to detail.
Detailed Integration Consultation: We initiated the project with a deep-dive consultation, requesting technical drawings and measurements of the client's current fermenters to understand their exact integration needs.
CAD Drawing Approval: We created a detailed CAD drawing of the proposed 600L tank and submitted it to the client. They were able to verify every dimension and port location, signing off with full confidence before we began fabrication.
Transparent Production & Quality Control: Throughout the manufacturing process, we provided the client with photos and videos, showing the quality of the welds, the polishing process, and the final pressure test. This transparency built trust and assured them of the quality they were about to receive.
Professional & Punctual Delivery: The tank was encased in a custom-built steel frame and protective wrapping to ensure it arrived in Manchester in pristine condition, ready for immediate installation.
The arrival and installation of the CASSMAN fermenter had an immediate and significant impact on Oak & Iron's operations.
Demand for Star Beer Met: By brewing a 600L batch of their hazy IPA, they could keep it on tap consistently, leading to a direct increase in sales and customer satisfaction.
Innovation Comes to Life: With the new tank free for experimentation, the brewery launched a successful series of small-batch seasonal beers, starting with a fruit-infused sour that became a summer hit.
Flawless, Zero-Downtime Integration: The fermenter was installed and connected to their glycol loop in just a few hours. The perfectly matched ports meant no on-site modifications were needed. "It just slotted in as if it had been here from day one," the head brewer noted.
A High-Return Investment: The founder praised the decision: "CASSMAN delivered more than just a steel tank; they delivered flexibility. The quality is world-class, and their attention to matching our existing setup was incredible. This single 600L tank is now the most versatile and profitable piece of equipment in our cellar, allowing us to both satisfy demand and innovate."
The Oak & Iron Brewing project highlights CASSMAN's role as a flexible partner for breweries at every stage of their growth. We understand that sometimes, the most impactful solution isn't a full new system, but a single, perfectly executed component. By delivering superior quality, deep customisation, and reliable logistics, we provide brewers in the UK and around the world with the exact tools they need to solve their most pressing challenges and continue to thrive.
For strategic growth and seamless expansion, CASSMAN delivers the perfect fit.
