Innovative Processes

CPL Line

Regularly reviewing our manufacturing processes allowed us to make many changes that contributed small but significant improvements over the years. Then in 2002 we had a serious breakthrough. The introduction of a continuous pipe laminator process (CPL) for our core pipe insulation products revolutionised an entire line.  It slashed production waste by over 90%. It also earned us a Queen’s Award for Innovation.

...and then there was CPL

Our unique continuous production process “extrudes” insulation in the shape of a pipe and avoids cutting from blocks of insulation, and thus creates minimal waste. Less than 5%. 
 

Future developments

The quest for further advances never stops. We constantly test new formulations to enhance the lambda performance in our CPL technology. Until recently larger pipe circumferences were still required to be cut from block, as they could not be manufactured using CPL. In 2014 we introduced slotted boards, which minimised the amount of waste from offcuts for these greater sizes. We are now in the process of commissioning a new line, bringing the benefits of CPL manufactured insulation to pipes as large as 610 mm.
 

OPTIM-R Manufacturing Line

In just two years they took the product from testing prototypes to full scale mass production, complete with BDA Agrément certification. OPTIM-R vacuum insulation panels are now solving problems for architects and builders in all kinds of projects.
 

The real challenge

The process is completely different from that used for our PIR and phenolic insulation. There was no existing production line to simply commission. We were faced with developing a process from scratch that was both scalable and that could handle the stringent requirements of VIP production.
 

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