Fliteway TechnologiesFlitewayTechnologies

Products

Custom-Designed Equipment

When standard equipment configurations do not meet your project requirements, Fliteway designs and builds fully custom environmental treatment systems. Our engineering and fabrication teams work together to deliver one-of-a-kind solutions — from initial concept through factory testing and field commissioning.

Discuss Your ProjectView All Services

Engineering for the Unique and Complex

Every remediation site is different. Soil conditions, contaminant profiles, regulatory requirements, space constraints, climate, and project timelines vary widely from project to project. While our standard product lines address the majority of remediation equipment needs, some projects require solutions that are designed from scratch.

Fliteway's custom design capability brings together our full engineering team — process, mechanical, electrical, and controls engineers — to develop integrated solutions for complex or unusual project requirements. With our in-house fabrication facility, we have the ability to build what we design, ensuring that custom equipment is practical, buildable, and maintainable.

Over 40 years in the environmental remediation industry, we have designed and built equipment for applications ranging from arctic remediation sites in Alaska to Superfund cleanups in the Southwest, from compact systems for urban locations with severe space constraints to large-scale treatment plants processing millions of gallons per day.

Custom Design Process

  • 1

    Requirements Definition

    We work with your project team to define the performance requirements, site constraints, regulatory standards, and design preferences that will guide the custom design. This phase ensures alignment on scope, schedule, and budget before engineering begins.

  • 2

    Conceptual Design & Cost Estimate

    Our engineers develop a conceptual design with process flow diagrams, preliminary equipment selections, and a general arrangement layout. A budgetary cost estimate is provided for project planning and approval.

  • 3

    Detailed Engineering

    Full engineering design across all disciplines: process P&IDs, mechanical layouts and piping, electrical single-lines and panel design, control system architecture and programming. Design submittals provided at 30%, 60%, and 90% completion for review.

  • 4

    Procurement & Fabrication

    Long-lead equipment is ordered immediately after design approval. Fabrication proceeds in our Cudahy, Wisconsin facility with in-process quality inspections and progress reporting.

  • 5

    Factory Testing & Delivery

    Completed equipment undergoes comprehensive factory acceptance testing (FAT) including electrical point-to-point verification, hydrostatic pipe testing, instrument calibration, and functional testing of controls and interlocks. Equipment is then prepared for shipment to the project site.

  • 6

    Field Support & Commissioning

    Our engineers provide field support for equipment installation, startup, and commissioning. We verify system performance against design specifications and train site operators on system operation and maintenance.

Our Engineering Disciplines

Process Engineering

  • •Treatment technology selection
  • •Mass balance and process modeling
  • •Equipment sizing and specification
  • •Pilot testing programs

Mechanical Engineering

  • •Equipment layout and arrangement
  • •Piping design and isometrics
  • •Structural steel and skid design
  • •3D modeling and coordination

Electrical Engineering

  • •Power distribution design
  • •Motor control centers
  • •VFD integration
  • •Hazardous area classification

Controls Engineering

  • •PLC programming
  • •SCADA and HMI development
  • •Remote monitoring
  • •Alarm management

Frequently Asked Questions

What types of custom equipment does Fliteway design and build?
Fliteway designs and builds one-of-a-kind environmental treatment equipment for projects that require solutions beyond standard product configurations. Examples include specialized multi-phase extraction systems, custom air stripper configurations, unique chemical treatment sequences, hybrid remediation systems combining multiple technologies, equipment designed for extreme environmental conditions (arctic, desert, marine), and systems that must fit within unusual space or weight constraints. If your project has unique requirements that standard equipment cannot meet, our engineering team can design and build a custom solution.
How does the custom design process work with Fliteway?
Our custom design process begins with a detailed discussion of your project requirements, site conditions, contaminant characteristics, and performance objectives. Our engineering team develops a conceptual design and preliminary cost estimate for review. Once approved, we proceed through detailed engineering design (mechanical, electrical, process, controls), procurement, fabrication, factory testing, and shipping. Throughout the process, we provide engineering submittals and review milestones so you maintain visibility into the design development. Typical custom equipment projects run 12 to 20 weeks from design approval to delivery.
Can Fliteway reverse-engineer or replicate existing equipment?
Yes. We regularly design replacement equipment for aging or obsolete remediation systems where the original manufacturer is no longer available or the original design needs updating. Our engineers can field-measure existing equipment, develop new engineering drawings, and fabricate replacement components or complete system replacements. We often incorporate design improvements, updated controls, and modern components during the replacement process to improve system performance and reliability.
Does Fliteway provide engineering stamps and certifications for custom equipment?
Our engineering designs are developed by licensed professional engineers and can be stamped in multiple states as required for permitting and regulatory review. Custom equipment is fabricated with appropriate certifications including UL 508A listing for control panels, ASME stamps for pressure vessels, UL 142 listing for storage tanks, and AWS D1.1 or D1.6 qualified welding procedures. We provide complete documentation packages including engineering drawings, calculations, material certifications, test reports, and O&M manuals with every custom equipment delivery.

Discuss Your Custom Equipment Project

Tell us about your project challenge. Our engineering team will evaluate the requirements and develop a custom equipment solution that meets your technical, schedule, and budget objectives.

Request a Quote