The Role of Insulation in Enhancing Efficiency Across Industrial Sectors

In an exclusive interaction with Industry Outlook, Subramanian N E, Managing Director of Saint-Gobain India - Insulation Business, shares insights on the pivotal role of quality insulation in improving energy efficiency, sustainability, and regulatory compliance. He discusses advancements in insulation technologies, retrofitting challenges, and their impact on operational performance, safety, and worker well-being. With over 25 years of experience leading high-performance teams in global corporations, Subramanian is an expert in P&L management, strategy development, business growth, brand building, and sustainability practices.

Given the increasing energy costs and sustainability mandates, how are industries like Power and Oil and Gas adapting their insulation strategies to achieve compliance with stricter energy efficiency regulations?

In today’s drive toward sustainable industrial practices, the "3 R's"—reduce, reuse, and recycle—serve as foundational pillars. By focusing on reducing energy consumption, reusing waste whenever possible, and recycling materials, industries can achieve a balance between operational efficiency and environmental responsibility. To optimize energy use and efficiency, companies are employing methods that reduce energy consumption per unit of output, such as waste heat recovery and preheating. A focus on improving boiler efficiency and reducing temperature drops across pipe lengths can lower fuel consumption and lead to substantial energy savings. One of the important methods to achieve this is by investing in high-quality insulation, as it not only prevents unwanted heat loss but also extends the lifespan of equipment and lowers maintenance costs. When making purchasing decisions, it’s beneficial to consider the total cost of ownership, which includes purchase, operating, and maintenance expenses, rather than focusing solely on initial costs. Quality insulation, paired with the right selection and proper installation, allows shorter payback periods, reduced process waste and downtime, lower risk of equipment corrosion, and decreased maintenance requirements.

How are recent advancements contributing to increasing performance and reducing thermal losses during production processes?

Companies are increasingly aware of the importance of prioritizing quality and focusing on lifetime costs. The government is also supporting this shift, which is evident in recent updates to the IS 8183 standard. The revised standard now covers applications up to 800°C, an increase from the previous limit of 750°C. With tighter tolerances for physical properties like density and thickness, clients can expect site performance to more closely match the engineering expectations set during project planning. Additionally, stricter limits on impurities such as chloride and sulfur will help the industry further reduce the corrosion-related wastage of metal components.

A new trend is emerging among users and consultants, who are closely scrutinizing the effectiveness of insulation in specific applications. Advanced software tools are now capable of calculating thermal heat loss, surface temperatures, and temperature drops based on globally recognized calculation methods. Users can factor in multiple variables, such as ambient temperature, wind velocity, cladding material, and fluid temperature. This comprehensive approach enables them to choose insulation materials that best meet their needs for minimizing heat loss, controlling surface temperature, and managing temperature drops, all while accommodating space constraints.

What specific challenges do companies face in retrofitting existing facilities with modern insulation technologies, particularly in terms of minimizing downtime and ensuring compliance with health and safety standards?

Retrofitting existing facilities is one of the most crucial and time-sensitive tasks in a plant. It often results in process slowdowns or stoppages, leading to production losses and, consequently, revenue impacts. Retrofitting also demands careful planning and attention to detail to ensure worker safety. Comprehensive measures are essential to minimize exposure to any hazardous materials, and strict adherence to safety protocols—including the use of protective equipment, ventilation, and other safety measures—is mandatory.

To minimize the time taken for retrofitting, customers can opt for value-added products that are designed and manufactured to suit specific applications. For instance, to insulate pipelines upto to 24-inch diameters, customers are advised to use pre-formed pipe sections. These are products with higher mechanical strength and are easy to apply, requiring less labor and time.

As noise pollution regulations tighten, what innovative acoustic insulation solutions are being implemented in heavy industrial environments, and how are these solutions impacting worker well-being and productivity?

Research shows that quieter workspaces boost employee productivity. As a result, more factories, especially those with pre-engineered or metal buildings, are using mineral wool insulation, such as glass wool and stone wool. This type of insulation blocks outside noise from sources like traffic, rain, and hail while also providing thermal comfort.

India’s Central Pollution Control Board (CPCB), which oversees noise pollution standards, mandates that equipment noise remains within specific limits. For instance, although noise at the source can reach up to 110 dB, diesel generator sets must not exceed a maximum noise level of 75 dB. To meet these standards, it is essential to insulate the genset walls. Similarly, noise control treatments are required for other factory areas, such as Air Handling Unit (AHU) rooms and engine rooms.

Effective noise management depends on using materials with high sound absorption and low sound transmission. The right combination of material, density, air gaps, and thickness can deliver optimal acoustic control without requiring much space.

Today’s market prioritizes safety, cost-efficiency, and sustainability, driving demand for versatile solutions. Mineral wool insulation has become a top choice for its strong insulation properties, fuel savings, use of recycled content, and fire safety, helping reduce the risk of fire-related damages.

What aspects of insulation a customer must consider to enhance personnel protection and fire safety in various industrial environments?

Industrial environments often contain hot and cold equipment, which can pose a risk of burn injuries or frostbite to nearby personnel. Effective insulation should be protected by keeping the equipment's surface temperatures within a safe range. For instance, if a pipeline carries steam at 250°C, insulation should limit the surface temperature on the cladding to around 55-60°C. To achieve this, users and specifiers need to consider operating conditions when selecting insulation materials. Stone wool is commonly used for this purpose, but buyers should be cautious of slag wool products marketed as stone wool. Slag wool, even at the same density as stone wool, is an inferior insulation product and thus may not maintain surface temperatures as effectively.

Additionally, mineral wool insulation complies with multiple fire safety standards, such as IS, ASTM, and BS. This non-combustible material does not spread flames and minimizes the release of toxic smoke, making it ideal for all applications, especially fire doors. These qualities offer occupants extra time to escape and reduce smoke inhalation risks in the event of a fire.

Lastly, our products are health-safe and bio-soluble, a crucial feature given the frequent exposure of installers and users to insulation materials. Customers can confirm this by looking for EUCEB certification, which verifies that the product meets specific bio-solubility standards. EUCEB-certified products fall within a defined range of chemical composition and are certified by a third party, ensuring their suitability for safe, long-term use.

Looking ahead, what trends or advancements do you foresee in insulation technologies that could significantly shape the future efficiency landscape of industrial sectors?

Many aspects of insulation remain unfamiliar to customers. In the future, the industry is expected to adopt a more comprehensive approach to selecting insulation, considering factors such as operating conditions, chloride content, shot content, sulfur content, and fire and health safety, among others. For guidance on selecting the right insulation, customers can refer to calculation methods in globally recognized standards like ISO and VDI.