Unilin Opens World's First Recyclable PIR Insulation Board Factory

Recently, Unilin has opened the world’s first comprehensive recycling plant for PIR (polyisocyanurate) insulation boards in Desselgem, Belgium, setting a new benchmark for sustainability. This advanced facility represents a significant achievement in Unilin’s efforts to reduce environmental impact and enhance the circularity of insulation products. With an investment of 8 million euros, the modern recycling plant enables Unilin to chemically recycle post-industrial PIR insulation boards and internal production waste into new PIR insulation products. Unilin’s new plant marks an important step in continuously lowering its carbon footprint and supporting sustainable building practices, as it is the first manufacturer in the insulation industry to achieve this milestone.

PIR insulation boards are mainly used for walls, floors, and roofs, known for their high thermal performance and long lifespan. These boards are manufactured through a chemical reaction between polyols and MDI (methylene diphenyl diisocyanate), resulting in an insulation material that surpasses traditional materials such as mineral wool, XPS (extruded polystyrene), and EPS (expanded polystyrene) in insulation efficiency.

The advantage of PIR insulation lies in its higher thermal insulation value per unit thickness, making it an ideal solution for energy-efficient buildings. Its lightweight structure is easy to handle and install, and the insulation performance of the panels can be maintained for decades, with almost no degradation over time. In fact, even after 50 years of use, the thermal insulation performance of PIR insulation material remains essentially unchanged, further solidifying its position as a durable and reliable material in the construction industry.

Unilin's recycling process

One of the biggest challenges faced by PIR insulation products is circularity. Although PIR boards are recyclable, previous methods only allowed for mechanical recycling, which has its limitations. Unilin’s breakthrough lies in the development of a chemical recycling process that can transform waste PIR boards into raw materials for producing new PIR boards. This independently developed recycling process is a game changer. It consists of three steps: shredding, filtering, and chemical recycling.

The first step is to crush the PIR board into small pieces.

In the next phase, a specially developed internal program will be used to separate PIR material from the paper or aluminum foil on the board surfaces. The purified PIR is sent to a glycolysis reactor, where it is broken down into polyols and other components. Subsequently, the recovered polyols are reintroduced into the production process and combined with MDI to manufacture new PIR insulation boards. Through this process, Unilin is now able to meet up to 50% of its polyol demand, marking an important step in reducing dependence on virgin raw materials. Consequently, the company is enhancing the sustainability of its products while reducing waste in the construction industry.

The new recycling plant located in Desselgem is just the beginning for Unilin. The company plans to gradually increase the plant's capacity, initially focusing on recycling internal board waste and then expanding to include industrial post-consumer waste from construction sites. In 2024, Unilin plans to add a recycling plant in the UK, with relevant expansion studies already underway.

In addition to expanding production capacity, Unilin is also exploring further innovations in recycling technology. The company is researching techniques to recycle not only polyols but also the MDI component, which will make the recycling process closer to true circularity.

Unilin has also launched the "Unilin Recycling" program, an initiative aimed at collecting PIR waste from construction sites and sending it back to the company's recycling facilities. Through collaboration with the construction industry, the program ensures a steady supply of post-industrial PIR waste to support the recycling process. The "Recycling" program is an important part of the company's closed-loop PIR insulation strategy, designed to promote sustainable building practices across Europe.

The insulation materials division of Unilin

Unilin has firmly established itself as one of the largest manufacturers of polyurethane (PU) insulation in Europe. The company’s product range includes a variety of insulation solutions for residential, commercial, and industrial applications, with well-known brands such as Usystem, Utherm, Usafe, and Rezillo. Unilin operates eight production facilities in Western Europe, including Belgium, the Netherlands, France, the UK, and Ireland, and is currently building a new factory in Poland.

In addition to its pioneering work in PIR insulation recovery, Unilin's commitment to sustainability is reflected in all areas of its operations. The company continuously innovates to improve the environmental performance of its products, reduce its carbon footprint, and promote circularity in the construction industry. Unilin's investment in the De Selghem recycling plant is a testament to the company's leadership in advancing sustainable building materials. With the growing demand for energy-efficient insulation products, Unilin will play a key role in shaping the future of the construction industry.

Unilin is reducing waste and carbon emissions by becoming the first company to chemically recycle PIR insulation boards. They are also laying the foundation for a more sustainable and circular economy in the construction industry. The company's envisioned closed-loop PIR insulation system has now become a reality, with plans for further innovation and growth.