Insulation

24
Raw Material Use & Manufacturing Efficiency
(How much raw materials is used and how much waste is made)
Context
Kingspan Insulation Ltd. recognises the need to
reduce consumption of virgin materials in light of
increasing pressures on natural resources.
The Environmental Purchasing Policy ensures that
focus remains on waste elimination. The purchasing
department actively pursues materials and
technologies which reduce overall waste.
Historical Achievements & Ongoing Activities
l Quality and Environmental Management Systems, certified to ISO 9001 and 14001 respectively, are in place at both sites.
l Lean manufacturing techniques, Six Sigma, statistical process control (SPC) and supervisory control and data acquisition (SCADA)
have increased the conversion efficiency of manufacturing.
l The manufacturing facility at Pembridge has undergone a ‘World Class” manufacturing status review, which identified “World Class”
practices in 17 out of 19 areas. The two areas where “World Class” practices are not in place have been addressed.
l Since 2008, Kingspan Insulation has undertaken a number of initiatives to address the accuracy and consistency of data collection
systems at both manufacturing sites. The introduction of SAP has significantly improved matters and provides real time monitoring of
the manufacturing process.
l A performance cockpit tool has been developed to monitor trends and benchmark performance at each site. The software also
enables manufacturing to be monitored and a traffic light system is used to communicate deficiencies in the process.
l Factory hardware consists of best practice and most appropriate technology.
l Cost savings have been realised through reducing the length of long–cut boards with associated savings in materials consumed.
l The efficiency of the manufacturing process at Pembridge has been improved by ceasing production of a scrap-intensive product.
l Material inputs are closely monitored. Exact amounts of constituent materials are known and measured against product output.
l Refinements to the manufacturing process have significantly reduced the density of Therma TM products without compromising
performance. The density of Kooltherm ® products has also been significantly reduced. Both actions have decreased the use of
raw materials.
l In 2009, advances to the manufacturing process allowed Kingspan Insulation to reduce the thermal conductivity of all products
manufactured at Pembridge and Selby, and, as a result, Kingspan Insulation can offer thinner insulation products with lower material
inputs. Kingspan Insulation continues to look at ways to reduce the thermal conductivity of all products.
l The newer manufacturing line at Pembridge and the line installed at Selby have the facility to ‘flush–back’ left over chemical input still
in the pipes prior to a new product run. This avoids wasting chemical input and production of potential scrap product.
l Packaging materials have been substantially reduced. Scrap insulation boards are cut to form skids, thereby removing the need for
wooden pallets in storage and transit of most products.
l The use of wooden pallets to store and transport products has been further reduced by the introduction of EPS skids for most heavy
products.
l Wood pallets have been eliminated from virtually all incoming deliveries.
l Adjustments to the packaging process have reduced the amount of plastic shrinkwrap and tightwrap used for each pack of insulation
boards by approximately 25%.
l All printers default to double sided printing if able to, and individual personal printers are only in place where absolutely necessary.
l Production of promotional materials is determined against the anticipated number needed for distribution.