Industrial customer savings of $460,000 on energy bills.
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Customer Testimonials

ISSUE: A large client for PT Nukote Indonesia needed to reduce the surface temperature of a hot water pipeline from the variable 74-95 deg. C surface temperature to 65 deg. C or lower. They also wanted corrosion resistance to protect the pipeline and increase the lifespan. Their prior experience with corrosion under insulation (CUI) and the short lifespan of traditional insulations meant they needed a new technology solution.

PRODUCT USED: Nansulate® Translucent PT

SOLUTION: Nansulate® Translucent PT was spray applied to a 24" diameter hot water pipeline to insulation and provide corrosion resistance. Thickness applied was 310 microns (approx. 3 coats).

Temperature of pipeline suface before: 74 deg. C
Temperature of pipeline surface after: 59 deg. C

Nansulate® PT provided the combination of benefits that the client had been looking fore - effective insulation, corrosion resistance, moisture resistance, and longevity and consistency of insulating ability.

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ISSUE: Bandvulc Tyres is one of the leading suppliers of commercial remould tyres to the transport industry. They operate at the forefront of tyre technology using the best available machines and quality control systems. They needed to reduce heat transfer on heat exchanger plates used on equipment in their facility.

PRODUCT USED: Nansulate® Translucent High Heat

SOLUTION: "Bandvulc Tyres Ltd. applied Nansulate to the exterior of a heat exchanger plate. The first coat was applied thinly and left to set for just over 20 days. After this period, the coats were applied more liberally up until the 8th coat. The 8th coat result now shows a temperature difference of roughly 30 degrees C."

-Calum Williams, Bandvulc Tyres Ltd.
www.bandvulc.com

Note: Study was done before all 8 coats had completely cured. Nansulate reaches its full insulation ability after full cure.

Industrial Nanotech's Distributor for the UK is Weltex UK. Contact information can be found at www.nansulate.co.uk

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ISSUE: Sipetrol needed a solution for the pipelines on their AM6 offshore platform to reduce heat loss from the transported petroleum product.

Products Used: Nansulate® PT at an average thickness of 350 microns was applied to the exterior of the pipelines. The Surface temperature of the pipelines was measured to indicate reduction of heat loss.

SOLUTION: Prior to being coated, the average temperatur of the pipeline exterior was 140F (60C). After coating the lines with Nansulate® PT, the average pipeline exterior temperature was 107.6F (42C). Their average temperature reduction was 32F (18C). Nansulate® also provided corrosion protection in the severe marine environment.

ISSUE: Decrease production costs, improve energy efficiency, protect equipment from corrosion and moisture.

SOLUTION: Nansulate® Translucent High Heat offers an inexpensive means to increase the lifespan of equipment, protect against corrosion, and decrease the amount of energy used for equipment processes

"Why insulate? Why Nansulate?

Global competition forces manufacturing companies to reduce production costs, where energy and metal prices are increasing rapidly.

Therefore a good way to decrease production cost is to make maximum use of the energy available and to install systems with much longer usable lifetime.

We need to use more technology in both insulation and corrosion protection.

It is possible to insulate with conventional materials only to a degree because;

1. you cannot insulate wet areas,
2. conventional insulation does not prevent corrosion, sometimes increases it
3.  Useful lifetime of conventional insulation is much less,
4.  application of Nansulate is simple and cheap, but takes a longer time.
5. conventional systems do not offer long term protection against moisture.

We used Nansulate in our textile dyeing and finishing plant; especially for thermal insulation of dyeing machines which operate at 130 C. Our aims were

i) with a minimum surface temperature reduction of 70 C,
  a) decrease energy cost
  b) increase process stability(which would mean increased product quality and decreased re-work)),and process reproducibility 
ii)increase machine metal parts lifetime by increased protection against corrosion
iii) increase usable lifetime of cold water and steam valves
iv) decrease dyeing process times.

In this respect, we are aiming to achieve a minimum of 20% gain in energy consumption, and overall 10% reduction in unit material production cost.

You cannot buy energy cheaper, but with a good insulation,you can achieve maximum gains.

If you are looking for a solution to insulation as well as corrosion protection, offering long-term usage, Nansulate is the ideal solution"

Ahmet Turgut
Factory Manager
Erenko Tekstil
www.erenko.com.tr

Industrial Nanotech's Distributor for Turkey is Kolorgen Ltd. Contact information can be found on our Distributor Map

ISSUE: Minimize oscillation of the reaction temperture for dyeing machine to improve reproducibility (color consistency). Insulate to decrease amount of energy used in equipment process.

SOLUTION: Nansulate® Translucent High Heat was used to insulate the dyeing machine. Monitoring a process that takes place at 60C for a 60 minute reaction time; the steam-based heat-exchanger of the un-insulated machine needed 24 heat-on cycles, whereas the Nansulate® coate machine's heat-exchanger only needed 2 heat-on cycles. Nansulate® also improved reproducibility - helping to keep the color of the fabric identical.

"Importance of Temperature Stability in Reactive Dyeing Process

In reactive dyeing of cotton, there are 5 important process parameters. (temperature, pH(acidity/alkalinity), salt concentration, bath ratio, reaction time)

For right-first-time dyeings, and reproducable quality, all of these 5 parameters should be the same, every time.

Parameters like bath ratio, pH, salt concentration and reaction time is nowadays closely monitored and faultlessy administered with the use of computerized controllers.

Reaction temperature is closely related to heat losses, as a result the reaction temperature oscillates below and above the reaction set temperature. This oscillation of temperature causes variability in dyeing so that reproducibility is quite low.

For reproducibility to be acceptable, dyeing machine and piping and circulation assembly should have proper insulation.

In pipes and certain other parts, conventional insulation is possible.

The problem area is the insulation of dyeing machine itself. It has large areas for heat loss, also it needs to be kept at a certain temperature for a defined duration.

Therefore, it may be possible to have better reproducability by dyeing machine insulation.

We have closely monitored a dyeing process which takes place at 60 C for a 60 minute reaction time; the steam-based heat-exchanger of the un-insulated machine needed 24 heat-on cycles, whereas Nansulate machine's heat-exchanger only needed 2 heat-on cycles.

This proves that by proper insulation, heat losses are minimized, it also shows that oscillation of temperature is decreased.

With a Nansulated dyeing machine, we have observed that the colour of fabric was surprisingly identical to one another, whereas in un-insulated machine, there is always a small difference in colour.

Ahmet Turgut
Factory Manager
Erenko Tekstil
www.erenko.com.tr

Industrial Nanotech's Distributor for Turkey is Kolorgen Ltd. Contact information can be found on our Distributor Map

ISSUE: Need to insulate, reduce surface temperature, protect equipment from corrosion and moisture.

SOLUTION: Nansulate® Translucent High Heat was applied to inter changers and other equipment to insulate, protect against corrosion, and decrase the amount of energy used for equipment processes. Preliminary results showed a 20 degrees Centigrade (36 Fahrenheit) difference after a 3 coat coverage (approx. thickness of 7 mils).

ISSUE: Decrease LNG (Liquified Natural Gas) expense, improve energy efficiency.

SOLUTION: This Dyehouse, located in the Trakya region of Turkey, manufactures products for clientele which includes two of the largest sports apparel manufacturers in the world.

Nansulate® Translucent High Heat had been applied to all heat exchangers of the customer's dyeing machines. After monitoring closely their consumption of LNG (liquified natural gas) for a period of 5 months, it was shown that they experienced an energy savings of more than 20%. From this data, the company anticipates that their savings is approx. $40,000 per month in energy costs, and based on this data have contracted to have other areas throughout the factory coated with Nansulate®, such as their LNG burners, dye machines, fabric drying and ranges, steam pipes, valves and hot water storage tanks; with an expected further increase in the money they save per month on their factory's energy costs.

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ISSUE: Reduce tank surface temperature to safer levels, insulate tank to reduce heat loss.

SOLUTION: Nansulate® PT was used by a customer on a tank that melts butterfat. The exterior tank temperature was noticeably reduced, creating a safer environment for employees, and the insulation provided by Nansulate® increased the melting efficiency of the tank, saving money and energy.

"We used Nansulate paint last year to paint a 5m(3) heated stainless steel tank which is positioned outdoors at a company on Cobden. This tank is used for melting butterfat. We achieved a measurable difference in the contents of this tank...The outside of the tank was previously too hot to touch. With three coats of Nansulate applied, the touch was now warm to touch and there was a visual improvement to the melting efficiency of the product inside. We are very happy with the performance of Nansulate and intend on using it to paint future tanks."

Regards,
David Morabito
Project Engineer
Ultraspin Technology Pty Ltd
www.ultraspin.com.au

ISSUE: Condensation forming on overhead ducts in restaurant dripping down onto customers.

SOLUTION: Nansulate® Translucent PT was used by the restaurant to help control the condensation, aleviate the excess dripping, and insulate the ductwork. Nansulate's translucent appearance allowed for application without changing the look of the decor.

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ISSUE: LS Industries, a designer and manufacturer of large metal cleaning equipment for the industrial and automotive markets, needed to reduce surface temperature of industrial ovens to a worker safe level and to increase efficiency of oven insulation.

SOLUTION: LS Industries coated the exterior of five of their Heat & Block Blaster ovens which are used for cleaning engines by burning off residue at a temperature of 800F. The external temperature of the ovens after application and cure (7 mil dft) of Nansulate® Translucent High Heat dropped from 168F to between 100-115F and was safe to touch while in operation. Their customers were very satisfied with the results of the surface temerature reduction and increase in energy efficiency.

LS Industries now plans to offer Nansulate® on all their products requiring insulation, rust and corrosion protection.

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