Insulation industry news from Global Insulation

US: Knauf Insulation North America and the Michigan Economic Development Corporation (MEDC) have announced an investment of around US$35m at Knauf’s fibre glass inslation plant at Albion in Michigan. The upgrade is expected to convert and restart an idled production line, increasing production capacity by more than 30% and adding 34 new full-time jobs. It will use recycled bottle glass recovered through the state of Michigan’s Bottle Deposit Law as a raw material. The project is expected to be completed in late 2020.

“Keeping pace with the growing demand in the upper Midwest for quality loose-fill insulation products will be made possible through the expansion of our plant here in Albion,” said Kevin Keen, plant manager at Albion.

The Michigan Strategic Fund (MSF) has approved a US$200,000 Michigan Business Development Program performance-based grant in support of the project. The MSF also approved a 100%, 15-year State Essential Services Act exemption valued at US$780,000.

Germany: BASF is developing a pilot project to make insulation panels from plastics waste as part of its ChemCycling project. The company is making ethylene and propylene from the waste to use as raw material for further chemical manufacturing. Other projects the company is testing using waste plastics with include mozzarella packaging and refrigerator components.

“With our ChemCycling project, we are using plastic waste as a resource. In this way, we create value for the environment, society and the economy. We have joined forces with partners throughout the value chain to establish a working circular model,” said Martin Brudermüller, chairman of the board of executive directors and chief technology officer of BASF.

BASF feeds oil derived from plastic waste by an oiling process into the Production Verbund process. BASF gets this feedstock for the pilot products from Recenso in Germany. As an alternative, syngas made from plastic waste can also be used. The first batch of this oil was fed into the steam cracker at BASF’s site in Ludwigshafen in October 2018. The steam cracker is the starting point for Verbund production. It breaks down or ‘cracks’ this raw material at temperatures of around 850°C. The primary outputs of the process are ethylene and propylene. Under the mass balance approach, the share of recycled raw material can be mathematically allocated to the final certified product. Each customer can select the allocated percentage of recycled material.

BASF is working with its customers and partners, which range from waste management companies to technology providers and packaging producers, to build a circular value chain. Its next step is to make the first products from the ChemCycling project commercially available. However, technological and regulatory conditions need to be met on a regional basis before the project is market-ready.

North America: A survey by the North American Insulation Manufacturers Association (NAIMA) has revealed that its members used over 0.9Mt of recycled glass to produce residential, commercial and industrial thermal and acoustical insulation in 2017. The survey included data from both US and Canadian production plants.

Producers also used over 0.3Mt of recycled blast furnace slag in the production of thermal and acoustic insulation. Since the industry’s recycling program began in 1992, NAIMA estimates that its members’ plants have diverted an estimated 26Mt of recycled materials from the waste stream.

“Our industry is tremendously proud of the substantial use of recycled content in the production of energy saving insulation products,” said Curt Rich, president and chief executive officer (CEO) of NAIMA. “These products ultimately reduce building energy use and decrease our carbon footprint. Over the long term, the fibre glass and mineral wool insulation industry expects to continue using substantial amounts of recycled content in the production of insulation products.”

UK: Knauf Insulation has entered into a long-term contract with Veolia to support the construction of a glass cullet-processing unit next to its insulation production plant in St Helens, Merseyside. The unit will be constructed and operated by Veolia on land owned by Knauf Insulation. It will provide recycled glass for use in Knauf’s insulation products. Veolia has invested Euro11.6m into the unit it plans to build by the end of 2017.

“We are delighted to be working with Veolia on this project, which perfectly aligns our goals for sustainability and the circular economy. Given recent shortages impacting the construction sector, our customers can be reassured that we are working proactively upstream to further enhance the security of our supply,” said John Sinfield, managing director at Knauf Insulation Northern Europe.

The new facility will dry and refine glass into a ‘furnace ready cullet’, a recycled standard of glass that has been cleaned and crushed into small fragments. The cullet is then fed into a furnace where it is melted and spun into glass mineral wool.

US: According to Recycling Today, American Fiber Green Products Inc (AFBG), based in Tampa, Florida and Owens Corning, a Toledo, Ohio-based developer and manufacturer of insulation, roofing and fibreglass composites, have entered into a five-year agreement for recycling services. The deal calls for AFBG to recycle the fibreglass-related material generated at Owens Corning's Amarillo, Texas plant, which is currently being landfilled.

"The recycling plan in Amarillo represents continued progress toward Owens Corning's 2020 environmental footprint goals," said Doug Pontsler, Owens Corning's vice president of environment, health and safety and operations sustainability. "Concurrent with our progress to reduce waste generation, we've made securing more reliable recycling for fibreglass waste a top priority. The solution from American Fiber Green Products, which will convert our waste into useful, marketable products, will help us achieve our sustainability goals."

"AFBG is excited to provide recycling services to this market leader through our Amour Fiber Core subsidiary," said AFBG Chairman Kenneth McCleave. "This contract has been in negotiation for over a year and a half and will substantially boost revenue for AFBG. The project will commence upon completion of construction of our recycling and manufacturing facility in the Amarillo area. Construction is expected to take about 12 months. We expect a successful recycling program in Amarillo to be the catalyst to an expanded relationship between our firms and potentially include other Owens Corning facilities around the country."

US/Canada: According to a survey by the North American Insulation Manufacturers Association (NAIMA), US producers used over 0.70Mt of recycled glass in the production of residential, commercial, industrial and air-handling thermal and acoustical insulation in 2012. Canadian members used around 0.14Mt of recycled glass. The survey investigated members' use of pre- and post-consumer recycled materials in insulation products in 2012.

US and Canadian facilities used over 0.22Mt of recycled blast furnace slag in the production of thermal and acoustical insulation. Since the industry's recycling programme began in 1992, NAIMA members' plants have diverted around 20Mt of recycled materials from the waste stream.

"NAIMA members are committed to promoting sustainability by using recycled materials to produce energy-saving insulation products that improve a building's energy efficiency and reduce environmental impact," said Kate Offringa, President and CEO of NAIMA.