Thermal Seal Duct Systems INC

Thermal Seal Duct Systems INC designs and fabricates impervious, air-tight, water-proof ductwork systems that meet SMACNA and IMC 2015/2018 International Mechanical Code standards. They offer three distinct types of ducts—Star 2, Star 3, and Star 4—featuring double-wall foam insulation with stainless steel or galvanized skins, available in round or square dimensions. The company also provides 3-D CAD duct design, diffusers, return air boxes, and return drip pans, serving clients in food processing and industrial production sectors.

The company was founded in 1994 as American Metal Fabrication in Ponca City, Oklahoma, and officially began patenting their Thermal Seal Duct system in late 2004 to early 2005. They have expanded significantly since then, opening a facility in Rome, Georgia in 2011 and a new diffuser manufacturing location in Neosho, Missouri in January 2025. Their growth has been driven by high demand for their leak-proof duct systems, which have doubled their sales annually since 2005.

The business operates three distinct facilities: the main office at 27 Superior Dr. SE in Rome, Georgia; the Oklahoma office at 4209 N. Hwy 77 Frontage Rd. in Ponca City, OK; and the Missouri office at 4001 Doniphan Dr. in Neosho, MO. They employ a combined total of approximately 45 people across these locations, with the Oklahoma office handling fabrication for areas west of the Mississippi and the Georgia office handling areas east of the Mississippi.

The company's Star 4 Hygienic Air Duct is specifically designed for high-hygiene environments, featuring a stainless steel inside duct and either a galvanized or stainless-steel outside skin. This construction eliminates condensation, which prevents microorganisms and bacteria from entering the airflow, making it ideal for food processing facilities like those of Nestle, Hormel, General Mills, and ConAgra foods. The system is also impervious to air leakage and water contamination.

To get started, potential customers can request a shop tour to see the facilities firsthand, as the company explicitly invites curious visitors to check them out. They also offer consulting and design services, including 3-D CAD drawings for both existing and new construction projects. Clients can request a quote or contact the team directly to discuss their specific ductwork needs and installation requirements.

The company provides a limited lifetime warranty on their duct systems, but this warranty is contingent upon the duct being installed correctly to their standards. They use inspection robots and drones to verify that installation meets their quality control requirements before the warranty is valid. Customers must ensure that the installation is performed by a collaborating contractor who adheres to these strict quality protocols.

The business offers a variety of services beyond just manufacturing, including consulting, design, and installation support. They can supply diffusers, return air boxes, and return drip pans to help improve current air handling systems. Additionally, they refer clients to trusted installers who can ensure the duct systems are set up correctly according to their specifications.

The company's website states that they are available for shop tours upon request, allowing potential clients to see their state-of-the-art equipment and facilities. They also participate in industry events, such as the International Institute of All-Natural Refrigeration (IIAR) conference and heavy equipment expo, where they showcase their products at booth 838. These events help them gain new connections and demonstrate their capabilities to industry professionals.

The company's duct systems are designed to address deficiencies in prior methods, such as insufficient thermal insulation, oversized dimensions, and air pressure leakage. Their impervious design prevents water and contaminants from entering the air transfer system, which is a critical feature for maintaining air quality and system efficiency. This makes their ductwork particularly effective for applications where humidity, temperature, and air quality control are paramount.

The company's Ponca City office currently employs twenty-four people, while the Rome office employs twenty-one people. The Neosho facility was added in January 2025 to handle diffuser manufacturing and supplement duct fabrication when demand overwhelms the other locations. This structure allows them to concentrate on strictly duct fabrication in their primary offices while maintaining high production capacity.

The company's Star 2 and Star 3 duct systems are customized commercial air ducts, with Star 2 being a 2-star hygienic duct system and Star 3 being a 3-star hygienic duct system. These systems are available in both square and round dimensions, offering flexibility for different installation requirements. The Star 4 system is the highest tier, offering high hygienic performance for the most demanding environments.

The company's website mentions that they have been featured in news articles, including a recognition where American Metal Fabrication was named 2011 Industry of the Year by the Ponca City Chamber of Commerce. This award highlights their reputation for excellence in metal fabrication and duct system design. The company also maintains an active presence on social media platforms like Facebook and YouTube to engage with their audience.

The company's duct systems are praised by customers for their professionalism, efficiency, and high-quality workmanship. Reviewers consistently note that the technicians are friendly and experienced, completing installations without issues. The quality of the duct systems is described as excellent, with many customers expressing satisfaction and willingness to use the services again.

The company has a Trustburn rating of 4.5 out of 5 stars based on 8 reviews. The reviews range from 3 to 5 stars, with the majority being 5-star ratings. The most recent review was posted on August 28, 2023, and the oldest was posted on July 5, 2022. The high rating reflects consistent praise for their service and product quality.

The company's contact information includes a main office phone number of 706-232-3544, which is available Monday through Friday from 8:00 AM to 5:00 PM. They also provide fax numbers at 406-232-0344 for their various locations. Customers can reach out via these channels to discuss their ductwork needs or request further information.