Custom Solutions
Standard IBC totes do not fit every application. Our fabrication team designs and builds custom IBC configurations for specialized needs — from heated dispensing systems and multi-tank manifolds to fully integrated process modules. If you can describe it, we can build it. We bring engineering capability, hands-on fabrication, and deep IBC expertise together to solve problems that off-the-shelf containers simply cannot address.
8+
Custom build categories
100+
Projects completed
4 Steps
Project process
In-House
Fabrication capability
Describe Your Custom Needs
What We Build
Our fabrication capability spans a wide range of IBC customizations. Below is our core product catalog — and if your need is not listed, we still want to hear about it.
Heated IBC Systems
Integrated heating blankets or immersion heaters with thermostat control for viscous liquids like resins, glycols, chocolate, honey, and wax. Maintain optimal flow temperature without external equipment. Electric and propane heating options. Temperature control ranges from 80°F to 250°F depending on configuration. UL-listed heating elements and temperature controllers used on all systems.
Multi-Tank Manifolds
Connect 2–8 IBC totes in series or parallel with custom piping, valves, and flow control. Ideal for batch mixing, continuous feed systems, or large-volume storage where a single tote is insufficient. Manifold systems include isolation valves for individual tank maintenance without disrupting the overall system, pressure-rated fittings, and optional flow meters.
Mixing & Agitation Systems
Top-mount mixers with variable-speed control integrated into IBC totes. Electric or pneumatic drive options, multiple impeller styles for different viscosities from water-thin to high-viscosity paste products. Sealed shaft designs maintain container integrity and prevent contamination ingress. Motor mounts are custom-fitted to the container lid or top frame.
Custom Valve Configurations
Non-standard valve sizes, materials (PTFE, stainless steel, Hastelloy), and placement. Bottom, side, and multi-port configurations available. High-purity valve options for pharmaceutical and food applications. Sanitary tri-clamp fittings for CIP-compatible systems. All valve installations are pressure-tested before delivery.
Containment Enclosures
Custom-built secondary containment frames, drip decks, and enclosure systems meeting EPA SPCC regulations and facility-specific spill containment requirements. Available in HDPE, galvanized steel, and stainless steel. Sized for single totes to multi-tote battery configurations. Drain fittings, sight gauges, and manual or automated pump-out options available.
Mobile Dispensing Units
IBC totes mounted on wheeled frames or trailers with integrated pumps, meters, hose reels, and nozzle systems. Bring bulk dispensing to the point of use rather than running permanent piping. Battery or pneumatic pump options. Flow meter options include turbine, magnetic, and oval gear types. Applications include lubricant dispensing, chemical dosing, and fuel additive distribution.
Insulated Systems
Thermal wraps and insulated enclosures for outdoor use in extreme temperatures. Maintain product within specified temperature ranges year-round — preventing freezing in winter and overheating in summer. Rigid foam-in-place insulation or removable blanket systems depending on the need for access frequency. Solar-reflective exterior coatings available for hot-climate applications.
Process Integration Modules
IBC totes configured as drop-in modules for existing production lines. Custom brackets, quick-connects, sensor ports, and automation interfaces to match your process requirements. Level sensors, temperature probes, and pressure transducers integrated and wired to your control system interface. Designed for tool-free changeover where process continuity requires fast container replacement.
Engineering Capabilities
Our in-house engineering and fabrication team brings a broad set of capabilities to every custom project.
Mechanical Design & CAD
Our design team uses CAD software to develop detailed drawings for every custom build before fabrication begins. Customers receive drawings for review and approval. Design files are retained for future modifications or repeat builds.
Materials Engineering
We understand the chemical compatibility of HDPE, polypropylene, stainless steel (304 and 316L), carbon steel, PTFE, and other common IBC materials with a wide range of process fluids. Material selection is validated against the specific product your system will contact.
Process Piping & Fitting
Custom pipe routing in schedules 40 and 80 PVC, CPVC, stainless, and carbon steel. Flanged, threaded, and welded connections. Sanitary fittings (tri-clamp, SMS, IDF) for food and pharmaceutical applications. All piping designed and installed for minimum dead legs and maximum drainability.
Electrical Integration
Heater circuits, temperature controller wiring, motor control panels, and sensor integration. All electrical work is performed to NEC standards. UL-listed components throughout. Intrinsically safe designs available for hazardous location (Class I, Division 2) applications.
Structural Fabrication
Custom frames, platforms, and mounting systems fabricated in-house. MIG and TIG welding on steel and stainless. Powder coat or galvanize finishing. Load calculations performed for elevated or mobile structures to confirm structural adequacy under operating and transport conditions.
Pressure System Design
Manifold and piping systems designed to ASME B31.3 Process Piping standards where applicable. Pressure relief provisions included in all pressurized systems. Hydrostatic testing performed on all pressure-rated assemblies before delivery.
Instrumentation & Controls
Level measurement (ultrasonic, float, guided wave radar), temperature measurement (RTD, thermocouple), flow measurement, and pressure monitoring. PLC integration and HMI design for automated systems. Alarm and interlock logic designed to your specification.
Testing & Commissioning
Every custom build undergoes function testing at our facility before delivery: pressure tests, flow tests, heater function, agitator operation, and sensor verification. We provide a test report with results. On-site commissioning support is available for complex or large systems.
Documentation Package
Custom builds include: as-built CAD drawings, bill of materials, operating instructions, maintenance schedule, relevant component data sheets, and test reports. Documentation is provided in printed and electronic formats.
Detailed Project Process
Every custom project follows a structured four-phase process that keeps you informed, in control, and confident in the outcome.
Consultation & Requirements Gathering
The project begins with a consultation — in person at your facility, by video call, or by phone, depending on project complexity. We ask about the product being stored or processed, temperature requirements, flow rates, connections to existing equipment, regulatory environment, physical space constraints, and budget range. For complex projects, we may ask for facility drawings or existing equipment specifications. The goal of consultation is to fully understand what you need before we propose anything.
Design, Feasibility, & Proposal
Our team develops the technical approach: material selection, component specification, and system architecture. For complex builds, we create preliminary CAD sketches for review. The formal proposal includes a detailed description of the build, a bill of major components with manufacturers and part numbers, a fabrication timeline, lead times for long-lead components, project pricing broken down by phase, and any assumptions or constraints that affect the design. You review, ask questions, and approve before we proceed.
Fabrication with Progress Updates
After proposal approval and purchase order receipt, fabrication begins at our Bedford Heights facility. We provide milestone updates at key stages: materials received, structural fabrication complete, component installation complete, and final testing in progress. For large or high-value projects, we offer video or photo updates at each milestone. If any design question arises during fabrication that requires your input, we contact you immediately rather than making assumptions.
Testing, Documentation & Delivery
Completed builds undergo function testing at our facility. Testing is documented in a formal test report. The full documentation package (drawings, bill of materials, operating instructions, test report) is assembled. Delivery is coordinated using our transportation network or your preferred carrier for large systems. For installations requiring on-site commissioning, we can dispatch a technician to supervise startup and train your operators.
Post-Delivery Support
We do not disappear after delivery. Our technical team is available by phone and email to answer operational questions, troubleshoot issues, and advise on maintenance. For systems under warranty, any confirmed manufacturing defect is remedied at our cost. For modifications or expansions of delivered systems, we maintain the as-built documentation and can quote modifications quickly because we know exactly what was built.
Repeat Build & Scale-Up
Once a custom build is proven in service, scaling up is straightforward. We retain all design files, bills of materials, and specifications. Repeat builds typically quote faster, procure faster, and build faster because the design work is already done. Customers who start with a pilot unit often scale to 5, 10, or 20 identical systems over the following seasons — and each repeat build benefits from lessons learned on the first.
Past Projects Gallery
A selection of custom IBC projects we have designed and built. Each project began as a unique problem without an off-the-shelf solution.
Chocolate & Confection Heated Battery
Four IBC totes connected in a heated manifold system for a confectionery manufacturer. Each tote equipped with immersion heaters and individual temperature controllers to maintain chocolate at 112°F for continuous casting line feed. Thermostatic alarm integration to prevent overtemperature product damage. System designed for daily drain-and-fill cycles with all-stainless sanitary fittings.
Mobile Lubricant Dispensing Trailer
Two 275-gallon IBC totes mounted side-by-side on a gooseneck trailer with dedicated 12V electric pumps, digital flow meters, and retractable hose reels for each product. Mechanical interlock prevents cross-product dispensing. Used daily at a fleet maintenance facility to dispense engine oil and hydraulic fluid to 50+ vehicles. Trailer DOT-compliant for road transport between facilities.
Resin Continuous Feed System
Six IBC totes in parallel manifold configuration supplying resin to a pultrusion line requiring 24/7 continuous feed. Automated level monitoring triggers low-level alerts when any tote reaches 10% capacity, giving operators time to connect a fresh tote before the line starves. Cascade valve sequence ensures consistent line pressure regardless of which totes are active. All wetted materials HDPE or SS316L for resin compatibility.
Chemical Dosing Station with Containment
Three IBC totes on individual HDPE drip decks enclosed in a welded steel containment berm. Each tote connected to a dedicated peristaltic dosing pump with digital flow control and remote on/off via 4–20mA signal from the plant PLC. Chemical feed rates adjustable from the control room. System handles sodium hypochlorite, aluminum sulfate, and polymer — each on a completely isolated circuit with no cross-contamination risk.
Agricultural Spray Blend System
Portable IBC-based blending station for a custom crop protection product formulator. Two 330-gallon totes with top-mount variable-speed agitators for mixing, a third tote for receiving the blended product. Transfer pump with flow meter logs batch totals. All components mounted on a common galvanized steel skid for forklift mobility around the facility. Designed for outdoor use in Midwest climate: UV-resistant materials and freeze-protection provisions.
Pharmaceutical Grade Transfer Station
Single IBC tote on a stainless steel frame with sanitary pump, tri-clamp fittings throughout, CIP spray ball, and digital scale integration. Designed for GMP compliance: all wetted surfaces electropolished SS316L, no dead legs in piping, fully drainable design. Batch records generated automatically from scale and flow meter data. Container exchange takes under 5 minutes with no tools required.
Outdoor Winter Glycol Storage System
Two IBC totes with 4-inch rigid foam insulation enclosures and electric heat trace on all piping and valves for year-round outdoor operation in a northern climate. System maintains propylene glycol solution above 35°F to prevent freeze-up at an outdoor district heating facility. Insulation enclosures are removable for container maintenance. Energy use metered separately for facility energy accounting.
Paint Line Feed System with Auto-Changeover
Four IBC totes in two-by-two auto-changeover configuration for uninterrupted paint supply to a continuous coating line. When the active tote reaches low-level, a pneumatic valve sequence automatically switches to the standby tote and alerts the operator to swap the empty. Eliminates production line stops due to paint starvation. All piping CPVC for compatibility with the solvent-based coatings in use.
Secondary Containment Battery for Chemical Storage
Eight IBC totes arranged in a double-row configuration within a custom welded HDPE secondary containment berm sized for 110% of the largest single tote volume, compliant with EPA SPCC plan requirements. Each row independently drainable. Berm fitted with a manual drain valve, a leak detector, and pump connections for rapid spill recovery. Grating over the berm allows forklift access for tote exchange without entering the containment area.
Industries We Serve
Custom IBC solutions are used wherever standard containers fall short. We build for a wide range of sectors.
Food & Beverage Manufacturing
Heated systems, sanitary fittings, CIP-compatible designs. FDA material compliance throughout.
Chemical Manufacturing
Corrosion-resistant materials, secondary containment, manifold systems. Hazmat-compatible designs.
Pharmaceuticals & Nutraceuticals
GMP-compliant designs, electropolished SS, sanitary connections, automated batch recording.
Agriculture & Crop Sciences
Field-durable portable systems, blend stations, seasonal spray equipment. Outdoor-rated components.
Petroleum & Lubricants
Mobile dispensing trailers, multi-product systems, flow metering. Safety-rated electrical components.
Water Treatment & Utilities
Chemical dosing stations, containment systems, PLC integration. Corrosion-resistant materials for hypochlorite and acids.
Paint & Coatings
Auto-changeover feed systems, solvent-compatible piping, continuous supply designs for production lines.
HVAC & Building Services
Glycol storage with freeze protection, outdoor insulated systems, building integration.
Composites & Specialty Materials
Resin feed manifolds, temperature control, high-precision flow for continuous manufacturing.
Automotive & Fleet Services
Mobile dispensing units, multi-product trailers, integrated metering for fleet operations.
Brewing & Distilling
Sanitary IBC systems for fermentation adjuncts, cleaning agents, and liquid ingredients.
Contract Manufacturing
Flexible container systems that adapt to multiple products, quick-changeover designs.
Service Area Coverage
Custom builds are fabricated at our Bedford Heights, Ohio facility and delivered nationwide. Consultation and on-site commissioning are available at all locations.
Zone 1 — On-Site Service Available
Ohio, Pennsylvania, Michigan, Indiana, West Virginia, Kentucky
Full on-site consultation, delivery by our own fleet, and on-site commissioning are all available within this region at no additional travel cost for standard projects. Our design team can visit your facility before fabrication to take measurements and evaluate integration points.
Zone 2 — Delivery + Remote Support
Illinois, Wisconsin, Minnesota, Missouri, Tennessee, Virginia, New York, New Jersey, Maryland
Custom systems are delivered via freight with full documentation. Remote commissioning support by video call. On-site commissioning available with travel arrangements quoted separately. Most systems are designed for straightforward self-installation with our documentation.
Zone 3 — Nationwide Delivery
All 48 continental states
Custom builds shipped anywhere in the continental US via our logistics network. All systems tested and fully documented before shipment. On-site commissioning available with travel arrangements. Contact us early in the project to discuss access, rigging, and installation requirements.
Pricing Transparency
Custom project pricing is inherently variable, but our approach to pricing is always transparent, itemized, and fixed at proposal acceptance.
What Goes Into a Custom Quote
Base container(s) cost, custom components and materials, fabrication labor (estimated hours), testing and documentation, packaging and freight. Each line is itemized so you understand exactly what you are paying for. Engineering and design time is included in the quoted price — we do not charge separately for drawings unless you need stamped engineering documents.
Fixed Price at Approval
When you approve our proposal, the price is fixed. We do not come back mid-project asking for more money unless the project scope changes materially at your direction. If we encounter an unforeseen technical challenge, we absorb it or discuss alternatives with you — never simply add it to the invoice.
Scope Change Management
If you change requirements after fabrication begins, we issue a formal change order describing the scope change, pricing impact, and schedule impact before we implement the change. You approve the change order before we proceed. Nothing changes without your explicit authorization.
Repeat Build Economics
Once a design is proven, repeat builds cost significantly less because design and engineering are already done. Component sourcing is established. Our team knows the build sequence. Customers who scale from 1 to 10 units see per-unit costs drop by 20–35% on repeat orders.
Turnaround Times
Custom project timelines depend on complexity and component lead times. These are our typical ranges for common project types.
Quality Guarantees
Our custom builds are backed by design and workmanship guarantees that reflect our confidence in our team and our processes.
Function Test Before Delivery
Every custom build is function-tested at our facility before it leaves. If it does not work exactly as specified, it does not ship. Testing is documented and the report ships with the system.
Workmanship Warranty
12-month warranty on all fabrication workmanship from the date of delivery. Any defect in our welding, assembly, wiring, or installation is remedied at our cost during the warranty period.
Component Manufacturer Warranty
All major components (heaters, motors, pumps, meters, controllers) carry their respective manufacturer warranties, typically 12–24 months. We facilitate warranty claims with manufacturers on your behalf.
Design Accuracy
The delivered system matches the approved proposal and drawings. If it does not — if dimensions are wrong, connections misaligned, or specifications missed — we correct it at no cost and within a priority timeline.
Documentation Completeness
Complete documentation ships with every build. If any document is missing, we provide it electronically within 24 hours of notification. Documentation is retained at our facility permanently.
Post-Delivery Technical Support
Technical support by phone and email is available for the life of the product at no charge for questions related to the system we built. Operator training and troubleshooting support are available beyond the warranty at a modest hourly rate.
Case Studies
Detailed examples of custom projects that solved real operational problems.
Confectionery Manufacturer Eliminates Production Stoppages with Heated Manifold
A specialty confectionery manufacturer was experiencing daily production line stoppages caused by chocolate viscosity at ambient temperature. Their single-tote setup required frequent manual agitation and produced inconsistent flow to the enrobing line. We designed a four-tote heated manifold system with individual thermostat control per tank, maintaining chocolate at 112°F continuously. A central distribution manifold with a dedicated circulation pump provides consistent pressure and flow to the line. Production stoppages due to chocolate viscosity dropped to zero in the first month of operation, and the manufacturer eliminated the cost of two manual agitation positions. The system paid for itself within 14 weeks of installation.
Chemical Distributor Achieves SPCC Compliance Without Facility Construction
A chemical distributor received an EPA SPCC inspection finding requiring secondary containment for their IBC tote storage area. The building was leased and structural modifications were prohibited by the lease agreement. We designed a portable welded HDPE secondary containment system — eight individual drip decks for each IBC tote and a master berm enclosing all eight — assembled without any penetrations or permanent attachments to the building structure. The system provides 110% containment of the largest single tote and includes an integrated leak detection sensor. The distributor passed their follow-up SPCC inspection without any further findings. The portable system moved with them when they relocated to a larger facility two years later.
Water Treatment Facility Replaces Manual Dosing with Automated IBC Dosing Station
A regional water treatment authority was manually dosing sodium hypochlorite from IBC totes using portable pumps — an inconsistent process that was creating disinfection compliance variability. We engineered an automated three-chemical dosing station with peristaltic pumps receiving 4–20mA signals from the plant SCADA system, digital flow meters for real-time dosing rate verification, and alarm outputs wired to the control room. All wetted materials are compatible with the chemicals in use (hypochlorite, alum, polymer). Individual secondary containment drip decks with HDPE berm connect to a single recovery sump. Since installation, the facility has consistently met disinfection targets and eliminated manual dosing labor for three operators across two shifts.
Why Choose Our Custom Solutions
Custom fabrication is a relationship of trust. Here is why our clients keep coming back project after project.
IBC Domain Expertise
We know IBC containers from the inside out — materials, structural limits, valve configurations, and regulatory requirements. We design within real-world constraints, not theoretical ideals.
In-House Fabrication
Design and build under one roof means no communication gaps between engineering and fabrication. Changes are implemented immediately and accurately. No outsourcing surprises.
Fixed-Price Proposals
Price changes are only possible with a formal change order that you approve. You will never receive a surprise invoice for unforeseen complications.
Tested Before Delivery
Every build is fully function-tested at our facility. We find and fix problems before they reach your facility, not after.
Full Documentation
As-built drawings, BOM, operating instructions, test reports. Your system is documented for maintenance, future modifications, and regulatory review.
Regulatory Awareness
We design with awareness of EPA containment requirements, FDA material standards, NFPA electrical classifications, and ASME pressure standards. Compliance is built in, not added on.
Scalable to Your Growth
Pilot to production: we design first units with scalability in mind. Repeat builds are faster and less expensive. We grow with you.
Post-Delivery Support
Technical support for the life of the system. Operator training available. Modifications and expansions quoted quickly using retained design files.
Frequently Asked Questions
Common questions about our custom IBC solution design and fabrication services.
How detailed does my specification need to be before I contact you?
It does not need to be detailed at all. Many of our best projects started with a customer saying I have a problem — I need to do X and the standard container does not work. We help translate operational problems into technical specifications. You do not need to know what components you need, what materials are compatible, or how to engineer a solution. That is our job. Just describe what you are trying to accomplish.
Do you do one-off custom builds or only production quantities?
We build single units and production quantities. Many projects start as a one-off prototype that gets evaluated in service, then we scale. We do not have a minimum order quantity for custom work. A single highly custom unit receives the same engineering rigor and documentation as a run of twenty.
What materials do you work with for custom fittings and piping?
Our standard materials include schedule 40 and 80 PVC, CPVC, polypropylene, stainless steel 304 and 316L, carbon steel, and HDPE. For valves and fittings we also use PTFE, Hastelloy C-276, and specialty polymers for extreme chemical environments. Material selection is validated against the specific product your system will contact using chemical resistance data from material manufacturers and our own application experience.
Can you integrate IBC totes into an existing automated production line?
Yes. Process integration is one of our most common custom project types. We design IBC tote systems with the sensor ports, electrical interfaces, and mechanical connections needed to plug into existing automation systems. We need your existing PLC type, signal specifications, and connection point details to design the interface. If you have a controls engineer on staff, we coordinate directly with them to ensure compatibility.
Can you work with IBC totes we already own?
Yes. If you already have IBC totes you want to modify, we can evaluate them and build custom modifications to your existing containers. We will inspect the containers first to confirm they are suitable for the intended modification — structural condition, previous contents compatibility, and remaining service life all factor in. If your containers are not suitable, we can source appropriate base containers as part of the project.
How do you handle intellectual property for designs we develop together?
Custom designs developed for specific customers are treated as confidential. We do not share design details, drawings, or specifications with other customers. If you require a formal non-disclosure agreement before sharing your application details, we are glad to execute one — just request it before our consultation. For novel process designs, customers retain rights to their application concept; we retain rights to our fabrication methods.
Do you offer leasing or rental of custom IBC systems?
We do not currently offer formal leasing programs for custom builds. Custom systems are sold outright. For customers who need a system for a single project or season, we discuss the economics of purchase versus disposal or resale at project end — in many cases, a custom IBC system retains significant value and can be resold or returned to us for a buyback if it is no longer needed.
What is your process for handling a project that is more complex than initially estimated?
If during design or fabrication we identify complexity that was not apparent in the initial consultation, we stop and discuss it with you before proceeding. We present the situation, the options, and the cost/timeline impact of each option. You make the decision. We never proceed beyond a complexity gate without your knowledge and consent, and we never add to the invoice for complexity that should have been identified in the original assessment.
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