Insulation industry news from Global Insulation

US: Foam Systems has opened a new spray foam insulation plant at Norwalk in Connecticut. The producer claims it is the only such producer in New England. The company produces products including Thermoseal Spray Foam Insulation, Igloo Foam Insulation and others. It plans to open other plants across the US and provide private label services to other spray foam brands and to anyone who would like a private label spray foam insulation system.

“With the ever-changing environment in the spray foam industry given all the mergers and acquisitions, the only way to survive in the future is to open manufacturing locations across the US. We are fully committed to this effort and have multiple manufacturing facilities across the US under consideration” said Richard Ettinger, General Manager of Foam Systems.

US: Germany’s Covestro plans to spend Euro1.5bn on building a new methylene diphenyl diisocyanate (MDI) plant at Baytown in Texas. The new plant will have a production capacity of 0.5Mt/yr and production is expected to start in 2024. The investment at the existing site in Baytown is the largest single investment in the history of the company. It will replace the 90,000t/yr MDI unit at the site.

“Demand for innovative MDI materials will continue to grow for the foreseeable future and likewise promises attractive capacity utilisation rates. We have already announced a significant increase in capital expenditures, now it’s time to put it into action”, said Markus Steilemann, chief executive officer (CEO) of Covestro. He added that the investment would strengthen the company’s ‘leading position’ in polyurethanes.

Covestro is also running a global investment programme in MDI production capacity, including plans to double its MDI production at Brunsbuettel, Germany to 0.4Mt/yr from 0.2Mt/yr by the second half of 2019. Other parts of this initiative include the continuation and expansion of plants in Tarragona in Spain, Caojing in China and Antwerp in Belgium.

UK: Plans by Knauf Insulation and Veolia to tackle complains about the ‘offensive’ odour from a glass-recycling unit at Knauf’s St Helens mineral wool plant have been approved by the local council. The proposals include introducing a wet scrubber and extending the current dryerstack to 30m from 13m, according to the St Helens Star newspaper. These measures were suggested following an assessment with Odournet. Local residents have made complaints about the Veolia-run unit since it became operation in October 2017.

Belgium: Recticel’s sales from its insulation division have rallied following the resumption on methylene diphenyl diisocyanate (MDI) supplies after a shortage in 2017 and poor weather in the first quarter of 2018. Its sales rose by 2.7% year-on-year to Euro129m in the first half of 2018 from Euro133m in the same period in 2017. Earnings before interest, taxation, depreciation and amortisation (EBTIDA) increased by 60.6% to Euro14.2m fro Euro22.8m. It attributed the growth in profitability to price rises and efficiency gains. The company also said that the construction of a new plant in Finland, dedicated to the supply of the Scandinavian and Baltics markets, is on schedule to start up in late 2018.

UK: Knauf Insulation has strengthened its strategic partnership with Siemens Energy. The next phase of the collaboration will focus on enhancing efficiency at Knauf Insulation’s glass mineral wool plant in Cwmbran, South Wales. This follows previous work started in 2015 at the insulation company’s St Helens plant. Across the two plants, the partnership is expected to reduce CO₂ emissions by more than 5000t/yr.

“We look forward to partnering with Knauf Insulation to deliver a comprehensive energy management programme that will use intelligent technologies not only to monitor where consumption is taking place and to what extent, but also implement a significant reduction in energy use across the company’s UK manufacturing plant asset base,” said Steve Martin, Head of Strategic Transformation at Siemens UK.

US: Sixty protestors have met with the Charles Town City Council in West Virginia to complain about a new stone wool plant being built in Ranson, Jefferson County. They asked that the council do more research into the effects the plant would have on the local environment, according to the Martinsburg Journal. Rockwool broke ground on the project in late June 2018 and it is expected to open in early 2020.

Romania: Denmark’s Rockwool has started construction work on a new stone wool plant at Ploiesti in Prahova county. Production at the Euro50m unit is scheduled to start in 2019, according to the Ziarul Financiar newspaper. Local construction company CON-A has been placed in charge of the project.

Malaysia: Knauf Insulation plans to build a Euro120m glass mineral wool plant at Johor Bahru. The new unit will have a production capacity of 75,000t/yr. It is scheduled to be completed in early 2020 and will create 180 jobs in Malaysia as well as a further 60 new positions across the region.

“We have seen record sales due to increasing energy costs across Asia and more stringent energy-saving building regulations in countries such as Australia, Japan and Korea,” said Stuart Dunbar, Regional General Manager for the Asia Pacific Region at Knauf Insulation.

The new plant will use up to 80% post-consumer recycled glass in the manufacturing process and feature Knauf patented high compression packaging. All products will be made using Knauf Insulation’s Ecose binder.

The company also intends to use Malaysia’s shipping links to develop new distribution partnerships in South-East Asian countries and strengthen its presence in the markets of Japan, Australia, Korea, New Zealand and Singapore.

US: Rockwool has officially broken ground at a new stone wool in Ranson, Jefferson County in West Virginia. Once completed it will be the company’s second stone wool plant in the country. The project has had an investment of over US$150m and it will employ around 150 people when it opens. The unit is expected to open in the first quarter of 2020. It will manufacture a full range of Rockwool stone wool insulation products.

“Solid customer demand and strong market growth in the US and elsewhere reflects the reality that people are increasingly discovering the quality and advantages of our stone wool solutions. This is our second factory in the United States, which positions us well for future growth,” said Jen s Birgersson, president and chief executive officer (CEO) of Rockwool Group.

France: Two workers have been seriously injured by an explosion at Soprema’s Saint-Julien-du-Sault polyurethane insulation plant in Yonne. A third worker was also injured in the accident, according to Le Monde newspaper. An external company was carrying out work at the site when the incident occurred. Sparks from a grinder are believed to have caused a holding tank to explode.