Custom Tank Solutions for Global Industrial Heating Technology Leader
When Kanthal Thermal Processing, a leading global player in industrial electric heating technology and resistance materials, needed specialized tank systems for their new manufacturing facility in Concord, NC, they required more than standard off-the-shelf solutions. The project demanded custom engineering that would maximize space efficiency while maintaining structural integrity—a challenge that led them to Fiberglass Solutions through their trusted partner, Design Tanks.
Kanthal's new facility presented unique spatial constraints that required innovative thinking. Traditional round tanks, while structurally superior, wouldn't efficiently utilize the available square footage in their carefully planned manufacturing space. The solution required square tank configurations that could maximize floor space utilization while maintaining the structural strength necessary for their industrial processes.
"Most fiberglass tank manufacturers simply don't fabricate square tanks because of the engineering challenges involved," said Ben Bertram, president of Fiberglass Solutions. "Square tanks lack the inherent structural strength of round designs, but Kanthal's space optimization requirements made them essential for this application."
Engineering Custom Solutions for Industrial Demands
The project specification called for six specialized tanks: four with 2,800-gallon capacity and two with 1,900-gallon capacity, each measuring approximately 8.5' x 6.5' x 6' tall. Beyond the challenging square configuration, each tank required sloped bottoms to ensure complete product drainage—a critical feature for Kanthal's manufacturing processes where product recovery and contamination prevention are paramount.
Fiberglass Solutions partnered with a local manufacturer to develop a structural cage system that would be fully wrapped in fiberglass, creating the necessary structural support for the square tank design. The tanks were engineered to handle temperatures up to 160°F and equipped with custom drains and flanges for seamless integration with Kanthal's process equipment.
"The contents were relatively non-corrosive, which allowed us to fabricate the tanks using isophthalic polyester resin to optimize cost-effectiveness without compromising performance," said Bertram. "This material selection provided the necessary chemical resistance and temperature tolerance while keeping the project within budget."
Manufacturing Excellence and Installation Efficiency
All six tanks were manufactured at Fiberglass Solutions' Green Bay, WI facility, ensuring consistent quality control and precise adherence to specifications. The tanks were gel-coated white to provide a clean, bright appearance appropriate for Kanthal's new state-of-the-art facility while delivering an easily cleanable surface that meets industrial hygiene standards.
The manufacturing approach emphasized installation efficiency for the customer. Tanks were shipped ready for installation, requiring only placement and connection of the custom walkway system—minimizing on-site labor and reducing installation timeline disruption to Kanthal's facility startup schedule.
"Our approach was to deliver a complete system that the Kanthal team could simply set in place and connect," said Bertram. "The custom walkway platform system provides safe access for operations and maintenance while integrating seamlessly with their facility design."
Future-Proof Flexibility
A critical advantage of the fiberglass construction became apparent in the system's adaptability for future modifications. Unlike stainless steel alternatives, the fiberglass tanks can be easily modified as Kanthal's needs evolve—whether requiring different flange configurations, additional ports, or process modifications.
"This flexibility represents a significant long-term value proposition," Bertram said. "As manufacturing processes evolve or production requirements change, these tanks can be modified in ways that simply aren't possible with metal alternatives. It's engineering that grows with the business."
The project successfully delivered space-maximizing tank solutions that other manufacturers typically don’t attempt, demonstrating Fiberglass Solutions' capability to engineer custom solutions for challenging industrial applications.
Partnership-Driven Success
The Kanthal project exemplifies how strategic partnerships amplify specialized capabilities. The collaboration with Design Tanks brought together complementary expertise, while the structural cage partnership enabled innovative engineering that neither company could have achieved independently.
"This project demonstrates our ability to work within a network of specialists to deliver solutions that exceed what any single contractor could provide," Bertram said. "When industrial clients need custom engineering for challenging applications, our partnership approach ensures they get the specialized expertise required for success."