Author Archives: David Fay

1978 to 2018 Forty Years of TPFay.

2018 is a big year for TPFay (Kirkby) Limited as we’ve reached the impressive milestone of 40 years in business. We were incorporated on 27 July 1978.

TPFay 40 years Trading 1978 to 2018

TPFay Certificate of Incorporation  -But, Companies House spelled our name incorrectly, Kirby not Kirkby, so we were re-named later in 1978.

Certificate of Incorporation

Over the last four decades we may have come a very long way from our humble beginnings.The business was founded by Terry Fay, manufacturing in his garage, accompanied by his father Peter.

Terry and Peter (TPFay) began by purchasing elements manufactured by others and custom forming and assembling them to bespoke designs and repairs of existing heater units. With stock stored in all corners of the house, including the loft, the whole family was always always closely involved with the business, day and night. The dining room was used as the office, even the kitchen oven was used to dry elements before sealing.

Our present 12,000 square foot facility couldn’t be more different! We now have purpose built production to manufacture our own heating elements from scratch.

A long and eventful journey, but we are still located next to the house where it all started.

In our 40 years of trading, we have always worked hard to ensure our products stay at the forefront of the market and put this success down to a combination of innovative design, technical and delivery services, developed with our customers in mind.

We continue to invest time and money to improve our products and services to make the best products for each customer and their particular requirement.

flange heater manufacture

Water Boiler Element Production8mmLOY800AfterRollingImmersion Heater Stainless Steel

 

 

 

We’re incredibly proud to be a forward thinking, family run business with family values which remain true to this day.

We would like to thank; our customers and suppliers (past and present), from every part of the UK, and Worldwide, for continued support.

Our customers, for continually challenging us, making each day different, not allowing us to stand still.

Our suppliers who help us select the best products and services to enable us continually improve everything we do.

Last, but not least our team members, the entire TPFay family, past and especially present. You make us what we are.

We use all of the experiences gained over the past 40 years every day, and we use them to power forward for the next.

Here’s to another 40 years of success!

Farewell to Paul. Greetings to Alan.

It is with regret that we said goodbye to Paul Robertson in December. After 13 years he has decided to move on to another challenge with good company in the area, we wish him well.

With the start of 2018 we welcome Alan Daly to take up the role, of Packing operative, “Tzar of shipping Despatch and many things”. As with everything at TPFay, it will involve doing a bit of everything. We’re sure he will settle in quickly. Welcome to the team!

We will be recruiting again, for other roles very soon. We will post the roles and requirements shortly.

We Make-up for Make-up

Recommended to contact us by a friend (Our favourite kind of advertising) Mike Dargan of Dashbo Ltd, brought another new application for us.

Dashbo are a manufacturer of Theatrical and Special FX makeup. A new formulation needed to be heated in an insulated container, then maintained at a constant temperature.

Mike visited our factory bringing the container, and explaining the requirement.

Dashbo needed something that was hygienic, low watt surface temperature and easily removable to permit easy cleaning of the container and the element after use.

After discussing various options we designed a heater to fit the container for the first trial production batch.

Image of Heater design

Image of Heater design

A few simple designs were sent for approval. A pocket was incorporated for simple plug in digital controller.

 

 

Make-Up Heating Element Dashbo

Make-Up Heating Element Dashbo

If we can assist with the “Make-up” of bespoke heaters for your application please get in touch, call +44(0)3703505058 or email sales@tpfay.co.uk or fill in our contact form here. We will be pleased to help.

Question Mark Brewery Kettle Heater

Here we have a “Question Mark” shape brewery immersion heater. For a leading London Micro-Brewery.

Designed to create a rolling boil in your Brewing Kettle – removable for cleaning when required.

Easy fit and easy removal. Heat is concentrated around the lower circumference of your kettle / copper.

If you are puzzled by the question mark and have some of your own?

Just ask us we will show you how we can make one for your kettle.

QUESTION MARK SHAPE BREWERY IMMERSION HEATER.

QUESTION MARK SHAPE BREWERY IMMERSION HEATER.

QUESTION MARK SHAPE BREWERY IMMERSION HEATER.

Saving your bacon.

Saving Old Equipment, making customers happy by helping save cost. Mercury Rangemaster cooker.

Is it infuriating when you have a piece of equipment or an appliance you like or need to use, with time and use one component on it stops working properly or fails completely?

You contact the manufacturer and they advise the part is obsolete or discontinued. You search the internet for other suppliers of the part but there are none; what do you do?

That is just what happened to some of our customers recently. Within a few days we were contacted by two customers who have a very expensive range cooker.

These Mercury Rangemaster Cookers were integral to the kitchens of the customers and functioned very well but eventually the grill elements failed. It is a necessary function of radiant grill elements that they have high watt density elements that glow red when in operation; they will fail generally faster than elements used for other lower temperature operations (if elements never failed we would be soon out of business). This, expensive, and much loved and much used range cooker was now out of service for the sake of a grill element.

Hello David,

As promised, I’ve followed up on your request for some further information:

Does it Cook / Grill evenly?     YES

Does it Cook / Grill faster?      Not really sure, since we regulate the power to cook things at the right temperature/speed.  I can’t measure against the old element, because you have it, but it certainly has a much brighter glow and is hotter.

Is it fully controllable with the Existing controls?  YES.  The controls show no signs of excessive arcing/wear as a result of the increased current.

Did the element fit easily as a direct replacement? A better question is “Was the element an accurate replica of the original?” – the element is a complete pain to fit, but that’s due to the oven design not your handiwork!  The old element was difficult to remove.  However, I didn’t have to bend/cut/adjust/grind anything for your one to fit.  The original element screwed to a small plate that provided the earth post, and this plate then screwed to the back of the grill.  I think this is due either to an element change by design or the element coming from another application.  A small improvement would be for your mount-plate to be full size to save having to get the plate off the old element.

Would you recommend others to use this Replacement element?  YES, definitely.  This model of Mercury cooker was hand-made by Lincat.  The newer Mercury cookers are mass produced by Rangemaster and are nowhere near as solid/good quality.  It was a £3k cooker, so replacing an element for your cost after ten years seems to me to be perfectly reasonable.  Plus, you chaps are the only ones that (now) supply the elements – you’re onto a winner! (except that there probably aren’t that many of these cookers around).

My biggest concern was the increased current draw and how the house wiring handled it.  The cooker is on a 10mm cable and a 40A RCD, so the cable’s fine and the MCB can just about take it.  Some customers might have it on a 6mm cable and a 32A MCB – the cable will be fine but the MCB would need to be changed.  Current draw:

Small oven: 11.7A
Large oven: 9.7A (odd, I know, but it’s fan assisted).
Grill small: 7.8A
Grill full: 16A
Max draw with all elements lit (cold): 37.7A

These are measured at the consumer unit with a clamp meter.  The grill seems low based on the simple P=VI formula, but we do have slightly high voltage (c 250v) because we’re rural so are fed by transformed 11kV supply.  I’m not complaining, since I’ve not had to change the MCB!

Anyway, I hope this information if of use.

Regards,

G.

Another day, more happy customers. And best of all their bacon cooks evenly across the grill.

If you need an identical element you can purchase one on our product page here

Mercury Rangemaster Dual Grill Element Replacement

Mercury Rangemaster Dual Grill Element Replacement

A British Manufacturing Company

Amid all the talk of exit negotiations from the EU, upcoming trade agreements with countries around the globe, exchange rate worries, tariffs and duties, protectionism, the world of trade looks a little perilous right now.

So why not Buy British?

A British Manufacturing Company

A British Manufacturing Company

TPFay saw the perils of a shrinking UK market of suppliers in 2009, and decided to do something about it. Our supplier base in the UK was getting smaller, we could, and did, explore the world for additional and alternative suppliers for heating elements. There are many manufacturers to carefully choose from; but, even with the best quality products, logistics were always an issue. The sometimes random delivery time and fluctuating cost to ship goods around the world made us wary of looking to import our heating elements.

We invested heavily, in new plant and machinery, and quietly, began making our own straight length heating elements in 2011.Company History

We have gained security in our supply chain, can offer you rapid delivery, and can be assured of quality from start to finish in all aspects of our key product – Heating Elements.

Plus we have created and secured British jobs, we have done our bit to try to even out our little bit of the trade balance.

Our production techniques are unique and environmentally frugal.

TPFay are undoubtedly reliant on some raw materials that are sourced outside the UK but wherever possible we will use UK manufacturers and suppliers. We are not closed off to the prospect of global trade, we are keen exporters of our products, worldwide.

So we would like to urge you to Buy British, especially if you are considering buying heating elements, but more than that, if you can make a positive choice when buying or specifying any items. Ask questions of your suppliers, can it be British sourced. Obviously, cost is a consideration, but after shipping, import costs, potential delays and so many more factors, is a UK supplier really more expensive? Your order could make a difference, to your company, to your supplier and the UK economy as a whole. Give it a try. Give us a try.

A British Manufacturing Company

A British Manufacturing Company

BUY BRITISH

 

Going the extra Mile.

Going the extra Mile.

Once again we seem to have managed to delight another customer, this very kind lady has gone out of her way to remember to send us an email of thanks from a job we did a few weeks ago for a Hotplate Element for an old Moorwood Vulcan MasterChef PLUS E90-R-15. There was no identification on the equipment but we managed to recognise the element from a photograph emailed from Claire at Elevenses Bakery in County Armargh https://www.facebook.com/Elevenses-1770715849846092/ or https://www.instagram.com/elevenses.bakery/

She needed the element in a hurry, so we made a special trip to the Post Office to help get it there on time. Good Luck with your new venture Claire.

From: Claire Keenan 
 Sent: 06 December 2016 09:48
 To: Sarah Fay
 Subject: Re: Sales Invoice. From T.P. FAY (KIRKBY) LTD.

Hi Sarah

I have meant to email back before now, just wanted to thank you 
for going out of your way to post the element Royal Mail for me 
(based in northern Ireland), saved me making an extra payment 
and meant we had a working hot plate for the opening of our new bakery, 
many thanks for the help from you and the team at 
TPFay who identified the element we required from a photo, it was much appreciated.

Regards

Claire Keenan



We were really glad to have helped and it gives us a warm fuzzy feeling to get recognition for doing our job the best way we know how.

 

Thank you for saying, Thank you. We love feedback.

It’s really great to get a positive response from a delighted customer.

We really try to do the best for all of our customers, and it becomes the “normal” level of service. But when we get feedback, it really helps us know we are getting it right.


From: GRAHAM HAYES 
 Date: 10 October 2016 at 21:51:32 BST
 To: Sarah Fay 
 Subject: Re: Sales Invoice SIN______. From T.P. FAY (KIRKBY) LTD.
 Reply-To: GRAHAM HAYES 

Dear Sarah,

Just a quick e-mail to you to thank you and your team for 

an excellent job on my recent order. I had to ask for you to

push through the elements for me after a total break down

here at work. I had initially said that there was no hurry so

when you managed to get them done in just over 24 hrs,

well that was unexpected and very much appreciated.

Thanks again

Regards

Graham Hayes

Daily Wash Service Ltd.

Graham, Thank you for saying thank you. We appreciate it.

Here to Help

A breakdown at our customer left production stopped.

DAMS LOGO

 

 

We were able to help by making replacements within a few hours.

The message of thanks was really appreciated, by the whole team. But you are very welcome!


Hi Sarah
Thanks for the fast action on our order. Really pulled us out of a disaster. Thanks to the manufacturing people as well.
Regards
Stu
Stuart Masson | Manufacturing
DAMS Furniture Ltd. (Trading as DAMS International)
www.dams.com