Insulation industry news from Global Insulation

Austria: Knauf Insulation will build a €30m, 10,000t/yr mineral wool recycling plant at Ferndorf in Villach, Carinthia. When commissioned in late 2026, the plant will recycle both glass and stone wool insulation. Kleine Zeitung Online News has reported that the process will consist of melting and granulation of the materials for use in subsequent insulation production.

The Austrian government will introduce a landfill ban for mineral wool from January 2027, but the country currently has no recycling plants for the material.

Finland: Saint-Gobain Isover has commenced production at its upgraded Forssa glass wool insulation plant in Kanta-Häme. Financial Wire News has reported that production is powered by a 50:50 energy mix of biogas and hydroelectricity. The producer says that this will reduce the Forssa plant's CO₂ emissions by 1500t/yr.

Saint-Gobain Isover is Finland’s largest consumer of recycled glass, of which the Forssa plant uses 80% in its raw materials mix.

UK: Knauf Insulation plans to build a €202m, 100,000t/yr stone wool insulation plant in Shotton, Flintshire. The new Shotton plant will produce reduced-CO₂ insulation using a submerged arc furnace (SAF). It will be Knauf Insulation’s second in North Wales, along with its existing Queensferry stone wool insulation plant, also in Flintshire. The company’s other UK plants are in Cwmbrân, Gwent, and St Helens, Merseyside.

Managing director of Knauf Insulation Northern Europe Neil Hargreaves said "This project aligns with the Welsh and UK governments’ commitments to sustainability and the industrial vision for North Wales and Deeside. Using UK-first SAF technology, the new factory will support the need for safer, more energy efficient and sustainable buildings."

The new Shotton plant accords with the UK government’s €190m plans for a Flintshire and Wrexham Investment Zone, centred on ‘advanced manufacturing’ and intended to attract €1.19bn of private investments.

Germany: BASF has completed a pilot, with Frankfurt-based housing society ABG and external thermal insulation composite systems producer Sto, testing an insulation board based on expandable polystyrene (EPS) containing recycled material. Around 10% of the polystyrene was replaced with a recycled substitute during the test. The results showed that the newly developed board met the same quality standards as standard market products. The sustainability targets of ABG was one of the key impetuses for the project.

BASF used its Neopor F 5 Mcycled product in the test. It is a graphite-containing expandable polystyrene granulate that contains 10% recycled material. The recycled material comes from mechanically recycled EPS waste. The aim is to other byproducts for the production of Neopor Mcycled in the future, such as EPS off-cuts from construction sites.

Germany: BASF is set to expand production of its Neopor graphite-enriched expanded polystyrene (EPS) at its Ludwigshafen plant in Rhineland-Palatinate by 50,000t/yr. From its commissioning in 2027, the expanded line will help BASF to meet increased demand for the material. Neopor serves as raw granulate for use in the production of insulation materials for building envelopes. The company says that it offers a 30% greater heat retention than traditional EPS.

Director Stephan Kothrade said "Neopor is classified as a 'Pioneer' in the highest category of the Sustainable Solution Steering (Triple-S) sustainability assessment which BASF uses to evaluate all its products, and is part of BASF's Sustainable Future Solutions."

US: The Center for the Polyurethanes Industry (CPI) has awarded construction, automotive and packaging products company Woodbridge the 2024 Polyurethane Innovation Award. The award acknowledges Woodbridge’s advancement of life-enhancing products and initiatives over the two-year period of June 2022 – June 2024.

Woodbridge vice president, advanced products and chemical technology, Mike Irwin said "We are pleased that Woodbridge has been honoured with the prestigious CPI Award. Our scientists have developed a proprietary process to seamlessly integrate biogenic carbon into our polyurethane foam. The result is TrimVisible BIO, a novel product that reduces CO₂."

CPI director Jason Sloan "CPI congratulates Woodbridge on this remarkable achievement. Sustainability is at the top of mind for manufacturers and the value chain. Woodbridge's TrimVisible BIO illustrates how polyurethanes are helping drive progress with durable solutions, and CPI is proud to recognise and honour Woodbridge on this cutting-edge innovation."

Sweden: Paroc has broken ground on the conversion of its Hällekis mineral wool insulation plant from coke-fired production to the use of electric furnaces. The producer says that the upgrade will eliminate 80% of the plant’s CO₂ emissions. It is additionally installing new raw materials handling and filtration equipment at the plant. Work is scheduled for completion in 2027.

Nico del Monaco, Insulation President of US-based parent company Owens Corning, said "We have seen that the landscape for our industry in the Nordics is undergoing significant changes, with new CO₂ restrictions and expectations from customers. By proactively addressing these changes through projects like this, we can turn them into opportunities. This significant investment is an important step for not only our plant in Hällekis, but it also reinforces Owens Corning's mission to build a sustainable future through material innovation."

US: Carlisle Construction Materials has awarded a contract to Germany-based polymers producer Covestro to supply its 99%-reduced CO₂ bio-circular methylene diphenyl diisocyanate (MDI). Carlisle Construction Materials plans to use the materials in its polyisocyanurate (PIR) insulation boards. Covestro says that it will supply its Mondur CQ 489 product, which will be suitable for use across Carlisle Construction Materials’ Hunter Panels, SynTec, Versico and WeatherBond product ranges. The supplier says that switching to this MDI will save 2.4t of CO₂ emissions per tonne used.

Carlisle Construction Materials president Steve Schwar said "Carlisle Construction Materials has always been at the forefront of developing high-performance construction products that lead the way in sustainability. With our new bio-based rigid foam insulation, we are demonstrating our unwavering commitment to environmental responsibility, while ensuring that our customers have access to the most advanced building materials available. Our partners play a pivotal role in the realisation of our bio-based isolation."

Covestro’s head of performance materials Hermann-Josef Doerholt said "Covestro’s vision to become fully circular requires research and development advancements that directly support the Scope 3 goals of our customers like Carlisle. Covestro has some of the most aggressive sustainability and climate targets in the chemical industry, and the further we progress in developing solutions to achieve them, the more the effects resonate along the supply chain.”

North America: Kingspan Insulated Panels North America has released its second annual sustainability report, detailing progress in the third year of the company’s Planet Passionate sustainability initiative. In 2023, Kingspan advanced its use of renewable energy, converting its DeLand, Florida, insulation plant to 100% on-site solar power. The producer reduced its total Scope 1 and 2 CO₂ emissions by 5% year-on-year and its water consumption by 2.17ML compared to 2022. It partnered with Belter Tech to divert 454,000kg of polyisocyanurate (PIR) foam from landfill.

Director of Sustainability Brent Trenga said "Planet Passionate is transforming the business on all levels, recognised by our leadership, employees and the building professionals we collaborate with. We are proud of our 2023 achievements and continue to strive for new milestones in 2024."

US: Knauf Insulation has secured US$3.28m in funding from the Environmental Protection Agency (EPA) to develop and verify Environmental Product Declarations (EPDs) for insulation. Knauf Insulation will produce the EPDs based on comprehensive Life Cycle Assessments of its products.

Knauf North America director of sustainability Gabriela Fleury said "Transparency is embedded in our core values and a key component of our business conduct. It is imperative that our product documentation provides accurate, reliable and updated information to our stakeholders. This grant will leverage the development and improvement of EPDs, which not only allows clients to make informed decisions about lower embodied carbon products, but also indicate areas of improvement to lower greenhouse gas emissions throughout our operations. This grant represents a significant sustainability leap for all of our stakeholders. It enables us to enhance our EPD portfolio, meeting increasing market demands for product transparency."