custom chemical manufacturing

The Specialty Chemical Experts

YOUR PARTNER IN COMPLEX
CUSTOM MANUFACTURING

custom chemical synthesis

FutureFuel, a leader in custom chemical manufacturing, is known for its commitment to safety, reliability, quality, and collaborative partnerships. Our comprehensive package of capabilities on-site ensures that we provide a one-stop solution, encompassing every aspect of the manufacturing process.

Unmatched Custom Chemical Solutions

FutureFuel delivers customized chemistry solutions for a variety of applications. We partner with customers across diverse industries and applications that include:

  • GMP Pharma
  • Energy
  • Polymer Modifiers
  • Coatings, Adhesives, Sealants, Elastomers (CASE)
  • Cleaning Ingredients
  • Dyes & Pigments
  • Personal Care / Nutrition
  • Agriculture

We are your go-to source for designing and engineering a process from concept to commercialization.

The Custom Manufacturing
Process at a Glance

The Custom Chemical Manufacturing Process: Turning Ideas into Reality

The Customization Process: Turning Ideas into Reality

Our customization process begins with a customer’s target compound. Our development laboratories, staffed with highly trained chemists, tackle the challenge of creating a synthesis procedure. The Process Hazard Evaluation and Scaleup (PHES) Laboratory evaluates the process and ensures the safety of full-scale operations. Process Engineering scales it to the manufacturing plant while Project Engineering and construction groups turn the design into reality, delivering the final product efficiently. Already have a well developed technical package for your product? FutureFuel’s experienced teams facilitate a seamless technology transfer, ensuring a cohesive and efficient integration of your specifications into our processes.

Quality Assurance and Analytical Excellence with Specialty Chemical Manufacturing

Quality Assurance and Analytical Excellence

Our commitment to quality is unwavering. A fully equipped analytical laboratory operates 24/7 to support the manufacturing plant with rigorous quality control. We employ ISO 9001:2015, BQ-9000, and GMP quality control measures based on process requirements. Our quality assurance group ensures the validity of analytical results and upholds the integrity of the data, providing our customers with confidence in the reliability of our products.

Communication and Collaboration: Customer-Centric Approach

Communication and Collaboration: Customer-Centric Approach

Every custom chemical project at FutureFuel is assigned a dedicated team comprising a sales account manager, a chemist, and a chemical engineer right from inception. Regular meetings are scheduled to provide project updates and exchange technical information, fostering a free-flowing communication stream that enhances the development process to meet the unique needs of each customer.

Scalability and Flexibility: Meeting Project Demands

Scalability and Flexibility: Meeting Project Demands

Our batch and continuous manufacturing plants are equipped with over 80 reactors ranging from 1000-6000 gallons. Our facilities showcase the ability to handle projects of varying sizes and complexities from thousands to millions of lbs. Specializing in making difficult processes look easy, our infrastructure and long-term projects provide us with the scalability to deliver excellence across a spectrum of custom chemical projects.

Future Growth and Innovation: It’s All About the Chemistry

Future Growth and Innovation: It’s All About the Chemistry

Custom Chemicals is an area we are passionate about growing. FutureFuel has the facilities, capabilities and know-how to deliver the products you need. Each new project provides an opportunity to collaborate with our customers to deliver innovative chemistry solutions.

Some Of Our Synthesis Capabilities

Organic chemistry and manufacturing is the heart of FutureFuel.
We have experience with most of the common transformations in organic chemistry.

  • Acetoacetylation
  • Acetylation
  • Acid Chlorides
  • Acylation
  • Aldol Condensation
  • Alkoxylation
  • Alkylation
  • Alkylation, Reductive
  • Amidation
  • Amino Acid Derivatives
  • Aminoalkylation
  • Asymmetric Synthesis
  • Benzoylation
  • Benzylation
  • Bromination
  • Carbonylation
  • Catalytic Reduction
  • Chemical Reduction
  • Chlorination
  • Chlorosulfonation
  • Condensation
  • Cyclization
  • Decarboxylation
  • Dehalogenation
  • Dehydration
  • Dehydrogenation
  • Diazotization
  • Eliminations
  • Epoxidation
  • Esterification
  • Etherification
  • Extractions
  • Formylation
  • Friedel-Crafts
  • Halogen Replacement
  • Halogenation
  • Heterocyclic Chemistry
  • Hydrobromination
  • Hydroformylation
  • Hydrolysis
  • Hydroxylation
  • Methylation
  • N-Alkylation
  • Nitrosation
  • Nucleophilic Substitution
  • O-Alkylation
  • Organometallic Reactions
  • Oxidation
  • Phase Transfer Reactions
  • Polymerization
  • Quaternization
  • Rearrangements
  • Ring Closure
  • Saponification
  • Solvolysis
  • Sulfonation
  • Transesterification

Hazardous Materials Handled Safely

FutureFuel manages many different hazardous chemicals, prioritizing the safety of our employees and the environment above all. Our commitment extends across all stages of handling to include storage, usage, and disposal.

  • Acrylates
  • Acetaldehyde
  • Acetic Anhydride
  • Aluminum Chloride
  • Benzene
  • Bromine
  • tert-Butyl Acrylamide
  • tert-Butyl Acrylate
  • Chlorine
  • Chlorobenzene
  • Crotonaldehyde
  • Dichlorobenzene
  • Dimethylformamide 
  • DMSO
  • Ethylene Dichloride
  • Ethyl Mercaptan
  • Formaldehyde
  • 36% Hydrochloric Acid
  • Hydrogen Chloride (Gas)
  • 35% Hydrogen Peroxide
  • Isophthalic Acid
  • alpha-Methyl Styrene
  • 30% Oleum
  • Phenol
  • Phosphorus Oxychloride
  • Phosphorus Trichloride
  • Propylene
  • Sulfuric Acid
  • Styrene
  • Thionyl Chloride
  • Vinyl Acetate
Custom Chemical Manufacturing Partner

General Purpose Custom Manufacturing Equipment

FutureFuel has a wide selection of equipment to meet your unique process requirements to scale products from thousands to millions of lbs.

Batch Plant Equipment

    Reactors

  • 69 Multipurpose Glass Lined & Stainless Steel
  • 1,000 - 6,000 Gallons

    Distillation Stills:

  • 6 Glass Lined & Stainless Steel
  • 1,000 - 3,000 Gallons

    Distillation Columns:

  • 20 Hastelloy, Stainless Steel,
    Glass lined
  •  0.3 m (1 ft) to 0.6 m(2 ft) Diameter
  • 2.7 m (9 ft) to 4.6 m (15 ft) Tall

    Filtration Equipment:

  • 31 Nutsches
  • 11 Alloy C & Stainless Steel Centrifuges
  • 3 AutoFilter Dryers

    Miscellaneous:

  • 1 - Stainless Steel Flaker System
  • 44 - Weigh Tanks
  • 6 - Agitated Mix Tanks
  • Numerous Bulk Tanks
  • Refrigerated Warehouse

    Pollution Abatement:

  • 10 - Particulate Waste Scrubbers
  • 12 - Caustic Scrubbers
  • 2 - Regenerative Thermal Oxidizers
  • 2- Thermal Oxidizers

    Dryers:

  • 10 Rotary Cone Vacuum Dryers

Continuous Plant Equipment

    Reactors:

  • 21 Glass Lined & Stainless Steel Stirred Reactors (500 - 6500 gal)
  • 4 Carbon Steel Fixed Bed Reactors (50 - 60” X 20’)

    Distillation Columns:

  • 3 Glass Lined
  • 23 Stainless Steel
  • 4 Hastelloy
  • 1 Titanium
  • 1 Polymer Lined
  • 5 Carbon Steel

    Filtration Equipment:

  • 9 Solid Bowl Centrifuges Stainless (Largest 30” x 120”) (0.76m X 3.0m)

    Dryers:

  • 4 Ring Dryers

    Liquid/Liquid Extractors:

  • 1 Alloy 20 (42” X 22’)
  • 1 Stainless Steel (21” X 48’)

    Adiabatic Vacuum Crystallizers:

  • 5 Stainless Steel (48” X 12’)

    Scraped Surface Coolers:

  • 6 Chrome Plated (11 sq.ft.)

    Vacuum Flash Tanks:

  • 6 Stainless Steel (96” X 11’)
  • 1 Glass Lined (3000 gal)

    Evaporators:

  • 1 Stainless Steel Wiped Film Evaporator (125 sq.ft.)
  • 1 Stainless Steel Thin Film Dryer (25 sq.m.)

    Rotary Drum Coolers:

  • 2 Stainless Steel (66” X 30’)
Analytical Equipment

Analytical Excellence:
Setting the Quality Standard

FutureFuel has an extensive, fully-equipped analytical laboratory on-site to support a variety of key functions: 

  • Process & Product Development:
    Identifying the composition for developing new processes and products
  • Quality Control:
    Ensures products meet customer specifications and industry standards
  • R&D:
    Support new product innovation and growth
  • Optimization:
    Identify opportunities to increase efficiency or reduce cycle times in manufacturing processes
  • Regulatory compliance:
    Support adherence to customer and industry standards and regulations
  • Troubleshooting:
    Investigate potential issues in a process or product
Custom Manufacturing with the best Analytical Equipment

Chromatography

  • Liquid Chromatography (LC)
  • Liquid Chromatography Mass Spectrometry (LC-MS)
  • Gas Chromatography (GC)
  • Gas Chromatography Mass Spectrometry (GC-MS)
  • Ion Chromatography (IC)

Spectroscopy

  • FT-IR Spectrometers
  • UV-VIS Spectrophotometers
  • Inductively Coupled Plasma Optical Emission Spectrometers (ICP-OES)
  • XRF Spectrometer
  • UVF Sulfur Analyzer
  • NMR Spectrometer
  • Particle Size Analyzer
  • TOC Analyzer
  • Thermal Analysis
  • Thermogravimetric Analyzer (TGA)
  • Differential Scanning Calorimeter (DSC)

Wet Chemistry

  • Volumetric and Coulometric KF Titrators
  • Auto titrators

Sample Preparation

  • Microwave digestion system

Miscellaneous

  • Bomb Calorimeters
  • Cloud and Pour Point Analyzers
  • Flashpoint Analyzers
  • Rancimat
  • Viscometers

Your Needs, Our Commitment

Whether your immediate need is a unique chemistry solution, process scale-up, or an extension of your current manufacturing line, FutureFuel is ready to discuss how we can collaborate to deliver tailored solutions to align with your objectives.

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in mind?

Learn how our expertise can fast track and scale your complex chemical product.