Insulation industry news from Global Insulation

UK: Knauf Insulation plans to spend Euro5m to upgrade its mineral wool plant in Queensferry in Flintshire, Wales. The investment will deliver thermal and mechanical improvements, along with an increased portfolio of insulation solutions. It will also support the group’s Ecose Technology binder product.

“We are especially pleased to announce this investment at Queensferry, given the uncertainty many other businesses and investors currently face. That uncertainty applies to wider concerns around the impact of Brexit on economic activity, but also to key sectors we service such as the construction industry, UK energy and energy efficiency businesses,” said John Sinfield, Managing Director at Knauf Insulation Northern Europe. “This decision demonstrates that a drive on energy efficiency will deliver greater energy security, increased UK economic competiveness and help address environmental commitments. We would hope that the new government, and especially the new Department for Business, Energy and Industrial Strategy, considers these outcomes when exploring what its new strategy is to be.”

Knauf Insulation acquired sole ownership of its UK business in 2002. It has since invested Euro179m at its UK plants.

Poland: Rockwool has inaugurated a Euro80m mineral wool production line at its Cigacice plant. The new line will allow the introduction of a new portfolio focusing on products for flat roofs and exterior walls. It will also allow for improved product quality, higher production efficiency and improved environmental credentials.

“The investment in Poland not only gives us the opportunity to take advantage of the latest technology in producing innovative stone wool solutions, we are now also positioned for further growth,” said CEO Jens Birgersson. He attended the inauguration with the managing director of Rockwool Polska Andrzej Kielar and other local Polish authority figures.

US: Kingspan has announced a US$25m investment for its Frederick County, Virginia insulation plant. It plans to add 15 new jobs, buy new equipment and upgrade the facility.

The plant has about 120 employees, according to Ed Bates, a Director of Manufacturing and Technology at Kingspan. "We're moving forward with the project," said Bates. "It's underway and we'll probably complete it in 2017. We've already initiated some hiring and we'll complete the hiring by 2018."

The Frederick County plant is Kingspan's only facility in the US that makes building wraps and insulation. The company, however, has other facilities in North America and around the world.

The uptick in the building industry factored into the expansion, according to Bates. "It's not back at the level it was at its peak in 2006, but we've seen a nice rebound in construction and there's high demand for insulation products due to their energy efficiency," said Bates. "It's a great time to invest."

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.

US: Less than a year after reopening a shuttered plant, Knauf Insulation has announced plans to double production at its Chambers County plant in Alabama, adding up to 100 new workers. The expansion, which should be complete by the middle of 2015, will make the 800,000ft² plant one of the largest insulation plants in the USA.

The US$30m expansion includes a significant upgrade in equipment, according to Joey Viselli, Knauf's vice president for corporate and public affairs. "When this expansion is through, the plant will produce more insulation than it has ever produced before," said Viselli.

Knauf shuttered the plant in 2010 in response to the collapse of the housing market. Company officials credited Alabama State with recruiting them to return when the market began to improve. Viselli said that the decision to expand was based on continued positive growth in the national economy, the growth of Knauf’s business and an inviting business culture in Alabama.

France: Etex has invested Euro25m towards upgrading four of its French Siniat polystyrene factories plants in its gypsum division. The investment is intended to reinforce Siniat's market share of exterior polystyrene-backed plasterboards for insulation.

Euro12m has been allocated to the Rantigny plant to raise its annual production capacity of back liners and insulating façade panels to 500,000m3. Euro7m will go to the Château-Gontier factory plant and Euro5.5m to the Loriol plant to expand and automate production capacity. Euro0.5m will be used to complete the production line at the Villeneuve-sur-Lot plant.

Tartarstan: TechnoNICOL has announced that it is going to invest Euro4.24m towards upgrading mineral wool production at a plant in Tatarstan.

TechnoNICOL's plant in Zainsk will increase its capacity by 20%. Currently the plant has two production lines with a total capacity of 140,000t/yr. The plant started operation in 2007.

TechnoNICOL was founded in 1993 as a producer and supplier of insulating materials. It has representations in 33 countries and maintains 35 production sites in Russia, Ukraine, Belarus, the Czech Republic and Lithuania.

US: Knauf Insulation has been granted a building permit to construct an US$8.7m warehouse and logistics facility in Shelbyville in the US state of Indiana. At a tax abatement hearing, local attorney Lee McNeely, who represented Knauf, told the Shelbyville Common Council that the building is part of an expansion that will bring back a major line producing light fibreglass to the insulation producing plant, known as the 602 line.

"The warehouse will replace an old manufacturing building," said Joey Viselli, vice president of marketing for Knauf. "It just gives us a lot more flexibility to have a warehouse on site," he said.

The building was the subject of a tax abatement request in November 2011, which was granted by the council. According to the tax abatement documentation, Knauf plans to tear down an existing building and then build the new 285,000ft², pre-fabricated metal warehouse and office space. Knauf's main US office is located in the same town.

The abatement documentation further added that, "Knauf intends to demolish an existing structure and build a new warehousing and office facility in order to support additional production for a growing customer base."

Knauf reported the total cost of the project to be US$10.9m. The City of Shelbyville permit is for US$8.7m in construction. The project is expected to add about eight jobs, creating an additional payroll of US$319,000.

In June 2011 Knauf closed its plant in Lanett, Alabama with the loss of 146 jobs. At the time, a company spokesman had said that Knauf was affected by an ongoing slump in housing construction. Viselli said that the closure of the Alabama plant is one element that changes the demands placed on the Shelbyville location.

US: Johns Manville (JM) officially broke ground on a new commercial roofing single ply membrane manufacturing facility in Milan, Ohio on 8 July 2011. The production facility will manufacture ethylene propylene diene monomer (EPDM) roofing products beginning in the second quarter of 2012.

During the groundbreaking ceremony - which hosted local officials, members of the Milan community, media and JM leadership - JM Chairman, President and CEO, Todd Raba noted that "This is a great day for JM and it's really incredibly gratifying to see the level of community support. JM has a strong presence in the state of Ohio and we are excited to be part of the Milan community." This facility marks the company's third facility in Ohio, with representation in three lines of its North American businesses of Insulation Systems, Engineered Products and Roofing Systems.

Raba also noted that, "This is the right time to invest in enhancing our product portfolio and JM now has one of the broadest offerings of commercial roofing products in the industry."

"Everything starts with our customers," stated Bob Wamboldt, vice president and general manager of JM's Roofing Systems business. "With over USD125m invested in our commercial roofing business over the past five years, this is really the crowning jewel of a five-year effort. JM has dedicated substantial resources to underscore our commitment to the single ply business and ensure a strong future for our customers in this segment of the commercial roofing industry."