Cockayne provides the Caskmaster and Integrated Flowlog systems that are used in the majority of Scotland’s whisky distilleries, blending warehouses and bottling plants for the accurate filling and disgorging of casks. However, we also have clients beyond Scotland, and our expertise is valuable for a wide range of liquid management applications. Our main services are listed here but do also get in touch if there are any other challenges that we may be able to help with.

Cask filling
and disgorging

Industry-leading accuracy
Using Siemens Coriolis flow meters, our filling systems can measure fill volume to a +/- 0.1 tolerance.

High-speed filling
The use of a modulating slow-fill valve allows tight control of spirit level as it reaches the top of the cask.

Optimising cask utilisation
A capacitive sensor allows the entire volume of cask to be filled, maximising maturation store use.

Repeatable filling performance
The Siemens Coriolis flow meter offers +/- 0.05% repeatability on fill measurement.

Quick ROI
The Caskmaster 4.0 system minimises losses from overfills and under/over reporting of fill volumes. You can expect a return on investment in six months or less.

Flexible configurations for varying cask sizes and layouts
There is a pantograph arm available for use in single cask filling, and a goalpost frame and lance arrangement for palletised operations.

Seamless DRAMS integration
The Caskmaster 4.0 software and control integrates seamlessly with the DRAMS ERP. There is no requirement for additional control hardware or software licences.

Cask filling
Our pneumatically-controlled Caskmaster delivers significant savings with its accurate cask filling meter, reliably recorded on our Flowlog system. For some export markets, or when filling Intermediate Bulk Containers (IBCs), the Caskmaster can also be fitted with an Intrinsically Safe interface for precise batch control, whilst still retaining Caskmaster's pneumatic overfill protection facility.

As well as casks and IBCs, the Caskmaster can be used to fill other containers such as transit tanks, and its stainless-steel wetted parts with PTFE seals are ideal for use with a wide range of chemicals. The Caskmaster IBC filling machine can also be fitted with a vibrating fork level switch for an extra level of overfill protection.

The Caskmaster has been installed on several sites for ‘end filling’ of casks when used for palletised filling. The lifting mechanism is modified to suit the vertical lift operation required, and palletised cask filling can be designed to the customer’s requirement for single, two, three and six-headed systems.

Disgorging single and palletised casks
We have a range of cask disgorging options enabling up to six casks to be emptied simultaneously. Through our integrated Flowlog, we’re able to analyse and compare the colour and volume of the spirit and monitor the cask condition. This data enables distilleries to ensure operational efficiency and manage quality control.

Calibration
and servicing

Flow meter calibration
All types of flow meters, whether they are turbine, Coriolis or Vortex, can be calibrated by our experienced team of engineers.

Tank strapping
Cockayne can provide accurate, detailed measurement and calibration of storage tanks to ensure customers don’t encounter issues with stock losses. Updated calibration tables are an essential requirement for the spirits and distilling industry.

Transmitter calibration
Transmitter calibration needs to be a regular part of your calibration schedule. Whether you're looking for pressure or level transmitter calibration, Cockayne can provide a high-quality service at a competitive cost.

DSEAR and ATEX Assessments
We can support you with all aspects of DSEAR compliance – from hazardous area classification, risk assessments, equipment selection and the design of engineering solutions.

Machine Service Contracts
Cockayne offers service contracts on cask filling and disgorging systems with flexible payment options. Our service contracts include predicative maintenance and a provision for emergency call-outs.

Calibration
For more than 30 years, we have provided on-site calibration service of flowmeters, storage tanks, vessels and vats, gauging equipment and bottling instrumentation to many industries, including distilling, brewing, food and drink, pharmaceuticals, and chemicals. Our on-site calibration is achieved by flowing liquid (water or spirit) through a traceable Coriolis flow master meter with flowrates of up to 1000 l/min. We then match our calibration against a gauge or dipstick reading depending on your site preference. Calibration can also be carried out using certified stainless-steel proving vessels with a capacity of 250 and 500 litres.

We can provide calibration certification and highly accurate, HMRC-approved tank strapping tables/charts for all calibration work. We also calibrate level, temperature and pressure using calibrated and certified test equipment.

Servicing
We know that our customers require well-designed and reliable measurement, instrumentation and control systems. We also understand that these systems must have minimal downtime to ensure that your production process meets the demands of your business. To keep control systems running reliably and accurately, our multi-skilled service team provides regular maintenance and calibration programmes for the full range of equipment that we provide.

In the event of a system or equipment failure. our team has the ability to respond rapidly, and with over 30 years of experience, we can supply, repair and support legacy equipment that many others are unable to. Our comprehensive maintenance contract philosophy allows us to tailor and deliver a service that will match the demands of your plant availability targets.