TrueFit Filter Rack
How FAMCO Engineers Turned a Field Problem into a Fast, Custom Solution
When the HVAC industry began transitioning to new A2L refrigerants, one unintended consequence quickly made itself known in the field: existing filter racks didn’t fit the new air handlers, and contractors were left fabricating makeshift solutions on site. That added time, labor, and frustration to already demanding installs.
FAMCO was listening.
The idea for the TrueFit Filter Rack first came to light through a FAMCO Regional Sales Manager who spotted a gap in the market. Contractors were being forced to fabricate filter racks in the field because there simply wasn’t a ready-made option that fits the new dimensions or efficiency requirements. That problem was brought back to the engineering team, and two of FAMCO’s engineers, Nick Dodge (Engineering Manager) and Alex Herrington (Product Engineer), stepped up.
Nick and Alex took the problem seriously from the start. “The projects worth pursuing are the ones where we are solving a problem, especially a problem no one else in the market understands,” said Nick. “We could see right away this wasn’t just a product gap. It was a real-world issue slowing contractors down.”
The team hit the ground- literally. Nick traveled to Florida to meet with contractors and see the issue firsthand. “The base design requirements were pretty clear,” he said, “but what we uncovered in person were the mounting challenges and the way installers were physically interacting with the racks. The insight really shaped the product.” Nick was not only focused on the functionality of the design, but also implementing “quality of life fixes” that would make a difference for the installers.
Once the core problem was defined, the FAMCO engineering team moved quickly, having the initial concept within a couple of days. Alex shared, “It wasn’t perfect, but it gave us something real to test. We could share a product with the customers and iterate based on their feedback.” On a regular cadence, FAMCO’s engineering team, sales department, and manufacturing managers would meet to discuss the timeline and the next steps of the project. Within a few weeks, the TrueFit Filter Rack went through two major redesigns and several minor adjustments to make sure it fully supported the needs of the contractor.
Their biggest challenge was the variation of filter sizes. “Every manufacturer has slightly different tolerances,” Nick shared. “We had to create a design flexible enough to work across those variations, while still being easy to install.”
The TrueFit project was not just about building a product but also about building a partnership. It was about nurturing a connection and finding a solution that really worked. Contractors now don’t need to compromise or retrofit a filter rack for the air handler. FAMCO builds the rack to your specs, based on your exact needs. “It’s adaptable so you get what you need,” Alex noted. “Contractors are no longer piecing something together in the field.”
The story of TrueFit is also a reflection of FAMCO’s broader philosophy: contractors are the experts. At FAMCO, our role is to support contractors with products that work better because they’re designed from real feedback, not assumptions.
“Anyone can make a product that technically fits. What sets FAMCO apart is that we make products that work for the installer. That’s who we aim to help,” Nick explains.
And that service doesn’t come at the cost of time or budget with FAMCO’s adaptable and made-to-order manufacturing process.
When asked what they would like to change for the next project, Nick explained, “I would like to have more direct communication with the contractors. I would like to hear more of their feedback to accelerate the product development process. I want FAMCO to be their partner in their projects.”
If you’re a contractor facing a problem on the jobsite, FAMCO wants to hear from you. Whether it’s a custom vent, damper, or a filter rack that actually fits the new equipment, we’re ready to help you.
That’s why we are the contractor’s first choice.
