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

technical department

A dynamic technical department at the service of its customers

Good morning, today I would like to talk to you about an important department of our company: the technical office.

Nowadays the technical office must be more and more flexible, working in close contact with sales office.

The work of our technical department is supported by a solid modeling software called “Solidwork”.

Working with a mathematical 3D model allows us to be able to analyze the object at 360° and therefore assess its exact dimensions; in this way we do not risk losing some details that with the 2D drawing might not be clearly visible.

Thanks to a 3D model that faithfully reflects the object, as it is made and installed, surveys are no longer necessary; the product is modeled directly on the object to which it will be applied, making the engineering process more streamlined and safer in terms of dimensional errors.

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Davide Oldani – Technical Manager

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cromo esavalente

How to handle the possible presence of hexavalent chromium in industrial plants?

For months now, there has been talk about the growing problem of hexavalent chromium formation on insulated structures in industrial plants.

Why has there been a debate on this issue?

Because this compound, resulting from thermochemical reactions among metal alloys containing chromium and oxides in conventional insulation materials, is a safety threat.

The danger of hexavalent chromium

Hexavalent chromium is classified as a very hazardous substance, with toxic effects on the environment and serious risks to human health. It is, therefore, essential to understand which situations are at risk and how to deal with them.

Since we have clearly in our minds what happened in the past with asbestos, we cannot ignore the situation and take decades before we recognise the hazardous nature.

It is therefore vital to understand the conditions that facilitate its formation. This compound is the result of a thermochemical reaction that causes the oxidation of chromium (contained in many metal alloys), under certain environmental conditions with the calcium oxide contained in many conventional insulation materials.

The result is a compound called hexavalent chromium, which no longer volatilises below 800°C.

But what are the environmental conditions to pay particular attention to?

  • The presence of ‘old style’ insulating materials containing calcium, sodium or potassium.
  • The reaching of operating temperatures between 300°C and 600°C.
  • The presence of metal alloys containing chromium.
  • A specific percentage of oxygen in the working environment

Should all these conditions occur, an imaginary alarm bell must be set off.

How to deal with the problem

Recognising the presence of hexavalent chromium is crucial. During dismantling operations the presence of a yellowish powder is an important indicator.

In such cases, it is essential to act promptly:

  • disassembly of insulators must be carried out by properly trained personnel;
  • the result of rapid chromium tests can confirm its presence;
  • in the event of a positive result, it is important to proceed with immediate remediation;
  • handling of materials contaminated with this compound must be entrusted to experienced personnel capable of working safely;
  • contaminated materials must be disposed of properly

But what preventive measures can be implemented?

The aspect of prevention is very close to our hearts: in addition to correct information on these risks, what preventive measures can be implemented in industrial plants?

New Componit’s response, which is the result of intensive product research and development, is the design of calcium-free high-temperature insulation systems to ensure the safety of people and environment, in full compliance with international occupational and environmental safety regulations.

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training employees

Why choose a partner that invests in the training of its employees?

Today I would like to talk you about the constant investment our company makes in employees training and professional development programs.

I would like to explore the many benefits this has brought to our organization and employees.

When a company invests in employee training, not only the employees but also the customers benefit from it.

In fact, relying on a constantly updated supplier means collaborating with someone who: wants to stay in step with changing times and evolve technologically to improve its products and services.

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Fabric expansion joints: how to install them correctly?

Today we are going to talk about fabric expansion joints and their correct installation.

In other previous posts we have focused on: the materials we use to realize them, their maintenance and the advantages that they can entail in a plant.

Why dedicate an article to installation?

A correct installation of the fabric expansion joint is as fundamental as its production. I can have a product perfectly made, using the best materials, but if it is installed incorrectly, the fabric expansion joint is not really effective.

Safety first

It happens that companies get in touch with us to buy fabric expansion joints specifying that they do not need support for the installation .

However, it should be kept in mind that, the installation of fabric expansion joints by unskilled personnel entails a number of safety risks to employees, especially when the system is in operation or in half service. Just recently, two workers of one of our customers were injured, by getting burned while they were assembling our products.

In fact, fabric expansion joints are installed in parts of plant where fluids, in a gaseous state, usually flow and which, besides very high temperatures, may contain chemicals or acidic components. These characteristics make the installation step somewhat “delicate”; this is why it is an operation that should not be underestimated at all.

If the expansion joint is not installed correctly, fluid spills can occur and be a health hazard to operators who, as they pass in the vicinity of these areas, risk being burned or coming into contact with chemical agents.

It is not only people who are at risk, but also any equipment that is in the vicinity of an expansion joint which is leaking.

The operation of the plant

In addition to safety, which we would like to remember comes first, we have to consider the plant performance.

If there are fluid leaks, it means that the plant is not working to its full capacity. In such cases, there is a risk of compromising plant operation with the occurrence of sudden and recurring plant shutdowns.

This situation obviously leads to losses in efficiency and considerable economic damage.

The position of fabric expansion joint

A question to which usually we do not pay attention is space. In many cases the fabric expansion joints have to be installed in narrow spaces, difficult to reach. The operation area for the employees involved is limited and the risk of making mistakes is very high; as a result, the installation becomes more complicated.

And then, in light of these considerations: how can we properly install the expansion joint?

Our answer is: delegate the installation to specially trained personnel or provide for the supervision of skilled technicians. Only in this way, we can be sure to install properly the expansion joint and reduce the risk of occurrence of situations as described above.

We also must keep in mind that no fabric expansion joint has a 100% seal, therefore the proper installation is essential to avoid fluid spills or minimize this possibility.

For all these reasons, we at New Componit have created, within our staff, a division exclusively dedicated to installation or assembly supervision. They are specifically trained technicians with decades of experience on site, able to work anywhere in the world.

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Tipcheck, the energy audit to save money

More and more frequently we hear about Tipcheck, the energy audit. Especially those who work in chemical and pharmaceutical fields will have already heard about it and know the opportunities for energy savings that open up with this analysis.

Although the issue of energy saving is increasingly topical, also because of: increase of price and EU sustainability objectives, many companies still have doubts about this opportunity.

In particular, many people ask themselves: what an energy efficiency implies in practice, what benefits it entails but also what is the initial investment, as well as what is the repayment time.

So let us clarify.

Let’s start from Tipcheck, which, as I said, is an energy audit on plants, which has the scope of drawing up a detailed report about the possible thermal insulation interventions to be implemented in order to reduce energy consumption, achieving real and measurable energy savings.

It is a standardized instrument put in action by the Eiif, the European Industrial Insulation Foundation, with the aim of providing the industrial sector with tools and solutions to save energy and reduce CO2 emissions.

The audit can only be carried out by Eiif’s partner companies, which have been accredited by the certifying agency. This last point may seem obvious but it is not.

In fact, when a matter, such as energy saving, becomes so topical, there are many competent subjects or not who want to “sell” the ideal solution to save on bills.

So my first advice is: pay attention to the interlocutor with whom you choose to collaborate!

The advantages of Tipcheck

The Tipcheck audit highlights how a series of insulation interventions can bring immediate benefits to the company, such as:

  • reducing production costs;
  • increasing energy efficiency;
  • reduction of CO2 emissions;
  • improving process efficiency;
  • reducing risks to personnel and equipment;
  • increasing of business competitiveness.

But I want to remind you that Tipcheck is an audit, so a first step towards energy efficiency, which then a series of concrete insulation interventions should follow.

Furthermore, Tipcheck follows a standardized analysis protocol; therefore, when you reach the implementation step of the recommended indication stated in the report, it is suggested to collaborate with a supplier able to understand the specific needs of your plant and therefore propose the ideal solution.

I say this because recently we at New Componit worked with a company, in the tanneries field, for which we carried out a detailed energy analysis followed by a tailor-made intervention.

We have, in fact, installed insulating jackets in several hotspots which led to energy savings even higher than their expectations.

I finish by saying that, if today there are still many doubts about the benefits of insulation, I think that the Tipcheck is a great tool to overcome some unfounded reservations and evaluate the economic return (and not only) of an investment that still may scare some companies.

We at New Componit are official members of the Eiif (European Industrial Insulation Foundation) since 2019; our accredited staff has been certified to carry out plant inspections and draw up energy-saving insulation studies.

We aim to find insulation solutions, designed according to specific customer needs, focusing on three key factors:

  • the temperatures;
  • the reduction of emissions into the atmosphere;
  • the resulting economic savings.

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Maintenance of fabric expansion joint : what to know

When we speak about plant maintenance, the companies immediately think about activities that take a lot of time and money, without realizing that skipping the periodic maintenance can lead to serious problems.

In fact there is a risk of several problems that may result in sudden plant shutdown.

Can you imagine the damage to production, delays in delivery and customers waiting ?

Therefore, maintenance is NOT a waste of time.

If we talk about fabric expansion joints, the scheduled maintenance must be understood as an integral part of a correct production management.

In fact, the break of a fabric expansion joint can lead to interruption of production, or accident at the workplace.

In order to prevent these events, it is enough to plan periodic checks to find out any problems and intervene before they cause damage.

How to carry out maintenance?

First of all, we must keep in mind that fabric expansion joints are subject to wear, especially if they are subjected to extreme working conditions.

The first signs of wear should be repaired, if possible, or replaced.

After this fundamental premise, let’s see how to carry out the maintenance, step-by-step.

1. Drawing up a preventive maintenance plan

For expansion joints, as well as for other equipment, it is necessary to draw up an annual maintenance plant, taking into account also the type of expansion joint and the condition of the plant.

2. Identifying the maintenance personnel

Depending on the type of plant, a manager must be identified within the company and sufficiently trained to assess the state of the expansion joints.

3. Be in touch with the manufacturer

This point is fundamental and at New Componit we’ll never stop repeating it: the maintenance manager of the company must communicate with the manufacturer of expansion joints or with the company to which it was decided to entrust the controls.

The timing and the type of analysis to be performed, must be defined by expert technicians, depending on the needs of the plant and the working conditions to which the expansion joint is subjected.

4. Draw up a maintenance data sheet

All control and maintenance activities must be recorded in a special tab so that you can easily and quickly access this information.

5. Pay attention to the supplier

Usually companies that produce fabric expansion joints sell their products with a guarantee of several years, but do not take care of their maintenance.

It is therefore essential to buy the fabric expansion joints from a supplier who, in addition to the warranty, is able to support you throughout the life of his product.

We at New Componit not only provide you with the product but we offer a repair and maintenance service, that prevents problems or production interruptions due to a worn joint.

For this reason, we have designed the Efficiency Box® that allows us to respond to every type of customer need, in order to make production systems more efficient and safe.

Efficiency Box® includes:

  • Monitoring of the plant, carried out directly by our skilled staff;
  • Design and supply of the required interventions, with simple but technologically advanced solutions;
  • Installation by New Componit personnel or assembly supervision;
  • Direct assistance and immediate response with a dedicated toll-free number.

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