Insulation industry news from Global Insulation

Germany: Johns Manville (JM), a Berkshire Hathaway company, has celebrated the inauguration of a state-of-the-art polyester spunbond production line at its plant in Berlin, Germany.

The new Euro32m line is part of a strategic plan to support the growing demand for high-end polyester filtration media. The new line utilises newly-developed proprietary spinning technology and will increase the Berlin plant's spunbond lightweight capacity by more than 40%.

"The new capacity at our Berlin plant will benefit Johns Manville's global customer base," said Mary Rhinehart, president and CEO. "Customers will have even greater access to our high-quality filtration products and to a new generation of spunbond filter media for cabin air, air pollution control and liquid filtration applications. This new lines also puts Johns Manville in a prime position to handle continued growth and customer demand in the many global markets we serve."

The Berlin site was founded in 1919 as 'Spinnstofffabrik Zehlendorf AG.' In 1960, Hoechst acquired the plant and in 1967 changed the production from Perlon (artificial silk) to spunbond and filaments polyester. In 1999, JM acquired the Berlin plant from Hoechst Trevira. Plant employees produce and market Evalith™ polyester spunbond nonwovens mainly for the filtration, roofing and geotextile industry.

Finland: Walki is answering increasing market demand for multilayer laminates by investing in a new production line at its Valkeakoski plant in Finland. According to Walki, there is an extensive growth potential, particularly in the construction business.

The new line, which, according to Walki executive vice president of construction Kari Salminen, will be 'unique on the market,' will start operations in the first quarter of 2016. It will be highly flexible and will cater to several different product segments in addition to the construction industry, such as consumer packaging and the pharmaceutical industry.
 
This flexibility will significantly shorten lead times.

The European Union's 202020 target, which, among other things, aims at a 20% improvement in energy-efficiency, is putting pressure on energy-efficient housing. Efficient insulation is key in keeping heating and cooling costs down.
 
Along with a recovery in the European economy, the construction business is expected to pick up, which will have a significant positive effect on the demand for insulation solutions, particular in those products requiring multilayer facings.

"With this investment, Walki strengthens its position as the premium supplier of multi-layer laminates globally. Further, the investment supports our strategy to focus on the growing segments of energy-saving laminates for building purposes and on value adding consumer packaging solutions," said Leif Frilund, president and CEO.

Saudi Arabia: Saudi International Petrochemical Company (Sipchem) has commenced commercial operation of a cable insulation polymers plant owned by Gulf Advanced Cables Insulation Company, a Sipchem affiliate, at its complex in Jubail Industrial City.

The plant produces several types of cable insulation polymers that are used to fabricate electrical cable insulation materials. Gulf Advanced Cables Insulation Company will market the products. Such specialised products are considered part of the company's strategy to execute comprehensive transformation projects in addition to its existing products. The raw materials, low-density polyethylene (LDPE) and ethylene vinyl acetate (EVA), will be provided by International Polymers Company (IPC), a Sipchem affiliate. The plant will meet local and global demand.

US: Knauf Insulation's plant in Huguley Industrial Park, Alabama will double its production capacity in June 2015, according to Aaron Wine, plant manager. The plant currently produces 200t/day of insulation. With the expansion, that capacity will grow to 400t/day.

During the housing slowdown Knauf shuttered its Lanett plant, which was put back into operation in 2013. According to Wine, the plant makes batts of insulation and blow-in wool. With the new line that is being installed, the Lanett plant will have the capability to produce rolls of insulation as well. When the new line goes online, employment will grow to 215.

China: BASF has begun trial operations at its mononitrobenzene plant within the integrated 400,000t methylene diphenyl diisocyanate (MDI) complex in Chongqing, China. This MDI site covers an area of more than 50 hectares, including facilities of 400,000t/yr of Mononitrobenzene, 300,000t/yr of aniline, 400,000t/yr of crude MDI, and an MDI splitter with a capacity of 400,000t/yr. Mononitrobenzene is a precursor for the production of MDI, a component for polyurethanes.

India: BASF has unveiled its largest construction chemicals plant in Nellore, Andhra Pradesh. This is BASF's fifth construction chemicals plant in the country.

With its state-of-the-art technology and its strategic location close to regional growth centres, the plant will enable BASF to respond in a timely fashion to customers' needs in the southern part of India and to support them with high-performance solutions in the highly-competitive market.

"With the new plant at Nellore, BASF offers a comprehensive range of solutions to help construct buildings that are more energy-efficient, durable and require fewer resources for maintenance," said Ralf Spettmann, president of construction chemicals at BASF.

US: Officials of CertainTeed Corp, part of Saint-Gobain, have announced that the company will renovate its plant in Kansas City, Kansas, creating more than 70 new jobs over the next three years.

CertainTeed said that it has begun renovating its plant to begin production of fibreglass insulation products during the second quarter of 2015. Greg Silvestri, president of CertainTeed Insulation, said that the company is investing more than US$30m to re-engineer the plant's furnace and restart related production lines to give it greater flexibility to support its growing business needs.

South Korea: LG Hausys plans to increase sales of its phenolic foam (PF) insulation six-fold by 2018, which it produces from its plant in North Chungcheong Province.

"We will see a change in the construction market in Korea," said Kim Myoung-deuk, head of decorative material department. "Many people prefer remodelling their houses and eco-friendly materials will become more popular." LG Hausys's PF insulation has a thermal conductivity of 0.018W/mK, which is about twice as efficient as polystyrene insulator at 0.034W/mK.

LG Hausys began producing PF insulation in October 2013. It aims to post US$12.6m in sales in 2015, up fromUS$7.21m in 2014. Sales are expected to top US$45m by 2018. It is a challenging goal, considering the stagnating construction industry in the country.

"Until now, around 80% of the insulation market has mostly been polystyrene or polyurethane, but a move to materials with higher insulation performance and better fireproofing has been forecast," said the vice president of LG Hausys. "We will be able to achieve this challenging goal." Researchers have estimated that the market share of the high-performance insulator in the global insulation market will increase from 10% in 2015 to >30% by 2018.

LG Hausys plans to focus its business capacity on developing insulation products for fire doors and sandwich panels and expanding to China. The Chinese government is preparing to enforce an energy-saving policy that tightens the insulation level in buildings, especially in the north. Because of this, it is estimated that the Chinese high-performance insulation market will grow more than 50%/yr. "We expect the high-performance insulator market to grow continuously, on policies for fire safety and energy saving and because of growing consumer interest in reducing the cost of heating and cooling," said Myoung-deuk.

Russia: Paroc intends to expand its production in Russia by 1.5 times to 45,000t in 2015. So far in 2015, its capacity utilisation rate is 100%. In 2014, Paroc's Tver plant sold 29,000t of mineral wool.

Paroc is investing US$121m in a new thermal insulation production plant in Tver. The project will be implemented in three stages; 2011 - 2013, 2014 - 2016 and 2017 - 2020. The new plant will produce up to 50,000t/yr of mineral wool.

US: Johns Manville (JM) has announced plans to expand the capacity at its Scottsboro, Alabama, thermoplastic polyolefin (TPO) plant. The state-of-the-art TPO plant was first opened in October 2008. JM will complete the expansion in April 2015, increasing its total TPO production capacity by 20%.

JM's TPO formulation has remained unchanged since its launch and has proven to be durable under real-world conditions of heat and ultra-violet (UV) exposure. "Commercial Roofers Inc began installing TPO more than 10 years ago. We have found it to be installer-friendly and energy compliant. It has a long, useful life expectancy and is cost effective. This provides great benefits for the building owner," said Scott Howard, president of Commercial Roofers Inc.