See how Fibre Craft Industries engineered a complete FRP pultruded cooling tower package for a 230 KL per day ethanol plant, built to run reliably in one of Pakistan's toughest industrial environments.

Cooling a 230 KL Per Day Ethanol Plant, Without a Single Weak Link

Ethanol plants do not forgive. One undersized tower and the whole process slows down.

Their distillery converts sugar cane molasses into ethyl alcohol at 230 KL per day. A plant running at that scale needed cooling towers that could handle three very different heat loads, without downtime and without shortcuts.

We delivered three FRP Pultruded Structure Counter Flow Cooling Towers, one for each critical section of the plant, engineered and built entirely in pultruded FRP structure.

‍Cooling Tower for Co-generation and Distillation

This is the largest tower in the package, and it carries the heaviest load in the plant.

• Total cooling capacity of 2,880 cubic metres per hour, split across three cells
• Each cell rated at 960 cubic metres per hour
• Cools water from 42°C down to 32°C
• Runs against a 28°C wet bulb temperature with a tight 4°C approach
• PVC film type fills, minimum 19mm flute spacing, for maximum heat transfer efficiency
• Full pultruded FRP superstructure built to run continuously without corroding or weakening

Cooling Tower for Fermentation

Fermentation is sensitive. Get the water temperature wrong and yield drops.

• Total cooling capacity of 1,520 cubic metres per hour, split across two cells
• Each cell rated at 760 cubic metres per hour
• Cools water from 33°C down to 30°C
• Runs against a 28°C wet bulb temperature with a precise 2°C approach
• Splash type grid fills in polypropylene, chosen for this section's specific water quality
• Pultruded FRP structure, built for years of reliable service with minimal upkeep

Cooling Tower for Molasses and Spent Wash

Spent wash and molasses destroy ordinary cooling tower materials. This tower was built to outlast that punishment.

• Total cooling capacity of 610 cubic metres per hour, split across two cells
• Each cell rated at 305 cubic metres per hour
• Cools water from 42°C down to 32°C
• Runs against a 28°C wet bulb temperature with a 4°C approach
• PVC film type fills, minimum 19mm flute spacing
• Pultruded FRP structure engineered specifically to resist molasses and spent wash exposure

Why We Build in Pultruded FRP

Steel rusts. Timber rots. Pultruded FRP Structure does neither.

That is why FRP has become the standard for cooling towers in sugar mills, ethanol plants, and distilleries across Pakistan. It is lighter, stronger for its weight, and immune to the corrosion that molasses, spent wash, and humid process air cause in ordinary materials.

In Lahore's summer heat and inside a working distillery, that difference matters. It means fewer breakdowns, less maintenance, and a cooling tower that keeps running long after cheaper alternatives would have failed.

Built to Run, Not Just Built to Spec

This package covered more than three towers. FCI supplied and installed the complete mechanical scope, including fill media, drift eliminators, water distribution assembly and fan assemblies along with gearbox, shaft & motor. The system comes with dedicated staircase for ease of access. 

Every tower was engineered, fabricated, and erected by our own team, from first drawing to final commissioning.

That is the standard we hold every cooling tower project to, whether it is a single unit or a full plant package like this one.

Planning a cooling tower for your plant?

Talk to Fibre Craft Industries. We design and build FRP cooling towers for sugar mills, distilleries, and industrial plants across Pakistan, engineered for your process, your water, and your conditions. Contact our team to discuss your project.

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