Insulation industry news from Global Insulation

US: Owens Corning has received R-value certification across all its fibreglass and mineral wool batts and rolls sold in the US. This validation was awarded from the North American Insulation Manufacturers Association (NAIMA) following testing and validation by an accredited third-party laboratory.

Under the program, Owens Corning agreed to have a random selection of products regularly tested to verify compliance with the thermal performance requirements of the Federal Trade Commission's (FTC) ‘Labeling and Advertising of Home Insulation’ (16 CFR Part 460) regulation.

The R-value certification represents the latest in third-party verification Owens Corning has earned across its insulation product portfolio. It will be visible on its packaging later in 2019.

US: Researchers at Washington State University (WSU) have developed an alternative to extruded polystyrene foam that uses nanocrystals of cellulose instead of petroleum based products. The team, led by Amir Ameli, assistant professor in the School of Mechanical and Materials Engineering, and Xiao Zhang, associate professor in the Gene and Linda School of Chemical Engineering and Bioengineering, have also developed a manufacturing process to make the foam using water as a solvent.

The project is working on developing an environmentally friendly replacement for extruded polystyrene foam. The WSU team created a material that is made of about 75% cellulose nanocrystals from wood pulp. They added polyvinyl alcohol, another polymer that bonds with the nanocellulose crystals and makes the resultant foams more elastic.

“We have used an easy method to make high-performance, composite foams based on nanocrystalline cellulose with an excellent combination of thermal insulation capability and mechanical properties,” said Ameli.

The researchers are now developing formulations for stronger and more durable materials for practical applications. They are interested in incorporating low‑cost feedstocks to make a commercially viable product and considering how to move from laboratory to a real-world manufacturing scale.

US: Johns Manville has appointed John Vasuta as the president of its Engineered Products business. He will lead the business that manufactures glass fibre nonwovens, polyester spunbonds and glass fibres for the building and construction industry, as well as for automotive, industrial and residential applications. It operates manufacturing plants in the US, Germany, Slovakia and China.

Vasuta most recently worked at Bridgestone Corp. as president and managing director, Firestone Building Products International as well as Global Senior Vice President, Firestone Building Products. He joined Bridgestone as Deputy General Counsel and later held a variety of executive-level jobs, including president of Bridgestone’s 250 commercial store division and vice president of International Sales and Operations for building products. He holds a bachelor’s degree in engineering, an MBA and a Juris Doctorate from the University of Akron.

US: Lower sales and production volumes reduced Owens Corning’s earnings in the first quarter of 2019 although it said higher prices partially compensated for this. The net sales for its insulation business fell by 1% year-on-year to US$591m in the first quarter of 2019 from US$596m in the same period in 2018. Its earnings before interest and taxation dropped by 53% to US$15m from US$32m. The company’s overall sales grew slightly but earnings fell.

US: Germany’s BASF plans to launch the second phase of its methylene diphenyl diisocyanate (MDI) unit at its Verbund plant in Geismar, Louisiana. The first phase of the upgrade was set to double the company’s MDI production capacity to nearly 0.6Mt/yr from 0.3Mt/yr. The new US$87m investment will continue this process. Construction is expected to start in late 2019 with completion scheduled for 2021.

“With the development of the American market, BASF needs this investment to support the growth of our existing customers,” said BASF Senior Vice President Stefan Doerr. “The Geismar site is ideally suited for this investment thanks to the existing infrastructure, competitive raw materials and favourable business support from state and local governments. This investment also demonstrates our strong commitment to our employees, our community and our presence in Louisiana.”

US: Rockwool has started legal action against the Jefferson County Board of Education (BOE) describing its attempts to stop construction of new mineral wool insulation plant as ‘unlawful.’ Court documents filed by the Danish insulation company allege that the BOE is trying to buy land from Rockwool for a low rate to build a student support centre otherwise it has threatened to appropriate it under US condemnation rules. Rockwool contends that the BOE originally supported the new plant with tax breaks but has since change its mind as local activists have opposed the project.

Rockwool started construction work on its US$150m mineral wool plant at Ranson, West Virginia in mid-2018. Production at the site is scheduled to start in early 2020.

US: The National Insulation Association (NIA) has appointed Dana Vlk as its new president. The new directors and executive committee of the association assumed their positions for the 2019 – 2020 term at the NIA's 64th Annual Convention that took place in Nassau in the Bahamas.

The association’s 2019 – 2020 executive committee includes: Dana Vlk, Distribution International – president; John Lamberton, Irex Contracting Group - president-elect; Dave Cox, Owens Corning – secretary/treasurer; Joe Leo, Atlantic Contracting & Specialties – assistant treasurer; and Dan Bofinger, Specialty Products & Insulation - immediate past president.

US: Canada’s IKO plans to build a new US$70m plant in Hagerstown, Maryland. It will be the company’s sixth US manufacturing location. The 46,000m² plant and warehouse site will be used to manufacture will produce roofing and insulation products including polyisocyanurate insulation. It is scheduled to open in mid-2020.

"Hagerstown is another example of IKO's commitment to building the strongest and most state of the art production network in our industry," said Guy Tremblay, IKO's Vice President of North American Operations.

US: Knauf Insulation has won a 2019 Greenbuild Leadership Award for outstanding contributions to sustainable building by the US Green Building Council (USGBC). The insulation producer was recognised for providing innovative solutions that both reduce energy consumption and save resources. The USGBC said that Knauf set an ‘outstanding’ example for the international green construction industry through its commitment to Leadership in Energy and Environmental Design (LEED) and other green building practices and its corporate social responsibility commitment.

“Knauf Insulation serves as a model for the international community. Your commitment to corporate social responsibility and improving the quality of life is an inspiration," said Mahesh Ramanujamm, the president and chief executive officer (CEO) of USGBC and Green Business Certification.

The award was received on behalf of Knauf Insulation by its Sustainability and Product Regulatory Affairs Director Vincent Briard at Greenbuild Europe, an annual USGBC forum for sustainable building experts held in Amsterdam, Netherlands.

China/Germany/US: The Mannheim Court in Germany has found that Chinese companies Guangdong Alison Hi-Tech and Nano Tech infringed one of Aspen Aerogels’ European patents by selling infringing aerogel insulation products. As part of the judgments, the Mannheim Court issued injunctions prohibiting the offer, distribution, use or import of infringing products in Germany and held Nano and Alison liable to Aspen Aerogels for damages, court costs and some of Aspen's legal fees and expenses. The Mannheim Court's decision is subject to an appeal to the Higher Regional Court of Karlsruhe. In a related lawsuit, the Mannheim Court had previously issued a series of judgments against Hiltex Techniche Weefsels, a Dutch reseller of the infringing Chinese aerogels.

In addition, the German Federal Patent Court in Munich found the Aspen patent to be valid as granted in a patent nullity action initiated by Nano. The Munich Court's decision follows other unsuccessful challenges to the validity of Aspen's patents by Nano and Alison in the US and China.

"Our core strategy is to invest in the research, development, commercialisation and protection of our aerogel technology platform worldwide. These European patent wins, along with our 2018 victory at the US International Trade Commission, reinforce the scope and strength of Aspen's patent portfolio," said Don Young, President and chief executive officer (CEO) of Aspen Aerogels.