From Efficiency to Safety: Strategies, Benefits, and Real-World Applications of Industrial Thermal Insulation

It is not always the most expensive part that stops a system.

Sometimes all it takes is a poorly made joint that causes an invisible heat loss… and therefore performance drops, consumption increases, production stops.

This is how small details become big problems. Especially if they are underestimated.

A prime example? Heat sealing applied to fabric expansion joints.

When done with care and expertise, it guarantees maximum sealing and high performance.

When neglected or done poorly, it can generate heat loss, reduce the useful life of the expansion joint and in the worst cases, cause costly and unexpected system downtime.

What happens if the heat sealing is not perfect?

Heat sealing is a fundamental technical step in the assembly of textile expansion joints. It serves to seal the final layers of the expansion joint, blocking any possible heat or gas leakage.

The process consists of inserting a heat-sealing film between two textile layers, which are then pressed and fused with a plate heated to approximately 430–450°C for 3–4 minutes.

It seems like a simple operation. But it is not.

An incorrect temperature, uneven pressure or hasty application is enough to compromise the effectiveness of the entire expansion joint. If not done properly, heat escapes, system performance drops and the expansion joint basically no longer does its job.

A poorly heat-sealed expansion joint can last up to half its normal life.

This means more replacements, more costs and, even worse, more unscheduled downtime.

When space is limited, there is no margin for error

In real industrial plants, textile expansion joints are not installed under ideal conditions.

Work is often carried out in confined spaces, with reduced visibility and limited accessibility.

It is precisely in these contexts that experience makes the difference.

Heat sealing, when carried out by experienced operators with the right tools, guarantees:

• a durable seal,
• zero heat loss,
• maximum plant performance.

Underestimating an expansion joint can be costly

Textile expansion  joints are often perceived as a minor detail.

“They are inexpensive, we install them internally, no expert is needed”. These are widespread but risky beliefs.

When an expansion joint is poorly installed or heat-sealed carelessly, it becomes a weak point that can compromise the entire system.

Even the slightest failure can cause heat loss, reduced performance and, in extreme cases, days of production downtime.

At that point, the cost of the joint is no longer important.

What matters is how much it costs to get everything up and running again.

Proper installation is a job for specialists

The installation of a textile expansion joint is therefore not an incidental step.

It is a technical activity that requires experience, precision and in-depth knowledge of the materials and operating conditions.

Especially when working in confined spaces, such as boiler bottoms or large industrial plant ducts, every action must be performed with accuracy:

• the position of the expansion joint,
• the alignment of the layers,
• the preparation of the welding points
• heat sealing at 430–450°C for 3–4 minutes.

Even the smallest error at this stage can halve the useful life of the component.

This is why not all teams are able to guarantee the same level of reliability.

New Componit brings its own method to the field

New Componit does not just supply a product.

It arrives on site. It works in direct contact with the plant. It supervises or performs every single step.

Installation is managed by highly qualified teams, who also operate in complex conditions, where there is zero margin for error.

Each heat seal is made with professional tools, temperature controls, application times and layer sealing.

In addition, New Componit technicians directly support the internal teams of companies, including through training or on-site assistance.

Where precision, expertise and reliability are required, there is only one way to achieve a perfectly functioning joint:
rely on those who install it every day, all over the world.

New Componit installations do more than just make an expansion joint work: they optimise the performance of the entire system.

So, if you are replacing your textile expansion joints, trust those who do it every day in systems like yours.

Talk to a New Componit technician: we will help you plan each stage, choose the most suitable solutions and carry out a flawless installation.

Contact us today for a personalised consultation.

There is always a challenge behind every innovation.

For New Componit, that challenge began years ago: to imagine a fabric expansion joint capable of functioning even in the presence of insulation, without losing its mechanical properties and at the same time guaranteeing durability and safety.

An idea that is as simple as it is complex to implement, which has led to the development of a new generation of high-performance textile solutions: Airflex expansion joints.

When insulation becomes a strength

A fabric expansion  joint is not just a simple component. It is a key element within a plant, because it must absorb vibrations, compensate for movements and withstand often extreme temperature and pressure conditions.

With Airflex, New Componit has opened a new phase in the evolution of industrial fabric expansion joints.

The main innovation concerns the possibility of insulating the expansion joint externally, allowing it to operate at temperatures up to 800°C without compromising its efficiency. This is an important technical achievement, because traditionally insulation tended to reduce the joint’s ability to perform its function. With Airflex, however, insulation becomes an ally, not an obstacle.

But Airflex is not just synonymous with high temperatures.

The line also includes fabric expansion joints dedicated to ventilation, designed to work up to 150°C, with advanced acoustic characteristics that reduce sound vibrations and improve workplace comfort.

What makes Airflex a strategic choice

Airflex fabric expansion joints are not only designed to withstand stress: they are manufactured to offer performance and durability never before seen in other compensators.

Their main features include:

• Structural flexibility, making them ideal for absorbing vibrations and movements without mechanical stress.
• External insulation option, a key element in reducing heat loss and optimizing the energy efficiency of systems.
• Resistance to extreme temperatures, up to 800°C in models designed for high temperatures.
• Customized solutions, thanks to a tailor-made design process that starts with a study of the customer’s needs.

Not just expansion joints: a complete service

New Componit’s real strength lies not only in its products, but also in the integrated service system that accompanies every supply.

Today’s large industrial plants require partners who are capable not only of producing components, but also of following the entire product life cycle: from engineering to assembly, from maintenance to repair.

For this reason New Componit has created a team of specialists, ready to intervene anywhere in the world, offering a complete package that includes:

• Supervision and assistance with assembly,
• Rapid repair interventions to reduce costly plant downtime,
• Preventive maintenance services,
• Thermographic reports for monitoring operating conditions,
• Complementary carpentry and welding activities.

In addition  the Expansion Control System service takes customization to the next level, with:

• Ad hoc design, thermal analysis and test chamber simulations;
• 3D or 2D engineering for total project control;
• Production with premium materials and advanced technologies.

Airflex protects your plant from unexpected downtime

One of the highest costs for an industrial plant is not the price of the component, but the downtime caused by a failure.

Airflex fabric expansion joints, combined with New Componit’s maintenance and repair service, drastically reduce these risks, ensuring production continuity and real savings.

In an increasingly fast-paced and competitive industrial world, relying on standard solutions is no longer enough.

Airflex was created for those who want to guarantee maximum efficiency of their plants, reduce heat loss and have a technical partner always at their side.

Would you like to know how Airflex can improve the efficiency and safety of your plant?

Contact us for a free technical consultation.

At the heart of combined cycle heat recovery boiler (HRSG) plants, controlling thermal expansion is one of the most complex challenges, for maintenance personnel and plant managers. Thermal and mechanical stresses, irregular operating cycles and high temperatures put a strain on the seal and reliability of components.

In this critical context Piperflex®  the textile through-wall expansion joint, designed by New Componit, establishes itself as one of the most effective and long-lasting solutions. A strategic choice that combines resistance, reliability and control, responding to concrete and increasingly pressing operational needs.

But what makes Piperflex® so reliable even in the most extreme conditions? Let’s find out point by point with a concrete look at its performance on the field.

Beyond the limits of metal expansion joints: Piperflex^® in the most critical areas of HRSG plants

New Componit supplies textile expansion joints for all critical areas of combined cycle plants: from the air intake to the stack. In particular, Piperflex® is designed for the wall passages of HRSG boilers – an area subject to strong temperature changes, mechanical movements and high pressure.

This is where traditional solutions, such as metal expansion joints, begin to show their limits.

One of the strengths of Piperflex^® is the ability to compensate for large axial and lateral movements ,protecting the structural integrity of the system and reducing the need for frequent interventions.

Unlike metal expansion  joints – which tend to wear out quickly under “stop & go” operating conditions – Piperflex^® maintains high performance over time even in particularly unstable situations.

With a thermal resistance of up to 950°C and excellent gas tightness, this expansion joint is particularly suitable for the high temperatures typical of HRSG systems. Not only  it improves thermal efficiency, but it also helps to minimize the risk of dispersion and leakage.

Each Piperflex^®  expansion joint is custom-designed: it is made after a careful analysis of the operating conditions of the plant, thanks to advanced design engineering, technical simulations and tests in a test chamber. The production is completely internal, to guarantee full control over materials quality and precision.

Also the installation is entrusted to highly qualified personnel, for an impeccable and long-lasting result.

More reliability, fewer surprises: Expansion Control System service

Piperflex^® is not only an expansion joint. It is part of a comprehensive service that accompanies the customer at all stages: from design to post-installation maintenance. With the Expansion Control System program, New Componit provides a range of services designed to monitor the performance, identify potential problems and optimize plant management.

Technical support is provided by an international team of specialists, able to intervene anywhere in the world. This means controlled installation, on-site supervision, timely repairs and above all, preventive maintenance:an approach that prevents breakdowns, reducing operating costs and extending system life.

At a time when unplanned outages can cause considerable economic damage, having a joint that ensures operational continuity makes all the difference. Piperflex® is designed to resist, adapt and last and it does so without compromise.

Concrete benefits of Piperflex® include:

• Superior reliability compared to metal expansion joints, even under irregular cycles
• Maximum thermal resistance up to 950°C
• Ability to absorb axial and lateral movements
• Perfect gas tightness even under complex operating conditions
• Custom and in-house manufacturing, with engineering materials selected to ensure high performance over time
• Installation performed by certified teams
• Ongoing technical support and proactive maintenance

Piperflex® is also a strategic asset for HRSG plants. Choosing it means reducing unscheduled shutdowns, containing downtime and achieving a tangible return in terms of business continuity and long component life

The robustness of an HRSG plant is also built through decisions that affect the most critical and stressed areas, when we talk about elements exposed to extreme conditions, what matters is the quality of the design and the precision of the implementation. Piperflex® is much more than a textile expansion joint: it is a guarantee of performance, a protection you can count on and an investment focused on operational continuity and sustainability.

Want to improve comfort and performance in your plant with a tailored solution?