We've focused our sales to refineries, shipyards and food plants with thin, ceramic-loaded thermal insulation coating for over 13 years and have worked with food processors for several years. California-based tomato processing companies ConAgra, Del Monte, Independent Foods, Heinz and others typically use insulation coating on saturated steam-based (350F or less) cooking equipment (canning or dehydration-based) to retain heat, protect staff from burns and reduce heat in spaces. An obvious strength for thin insulation coating is it’s ability to perform in environments where traditional mass-based materials fail due to wet conditions (outdoor) or stringent wash-down procedures. In wet conditions, coating-based adhesion helps control corrosion under insulation (CUI) and allows visual inspections of surfaces. Though thin insulation coating may not hold heat as efficiently as dry, mass-based insulation, it’s ability to perform well in wet conditions is primary reason for using it outdoors. The energy loss calc by Del Monte Foods (attached) is based on testing and compares steam condensate volumes used in cooking equipment and steel pipes. This type of indirect test has advantages over traditional tests used for mass-based, conductive materials that require 1” thick layers as a basis. Del Monte Food’s engineer, Bill Riker, used steam traps to collect condensate from 2 side-by-side 6” steel pipes (1 pipe coated with thin insulation coating and 1 pipe painted with white paint). The side-by-side pipe comparison generated a 24% cooled condensate volume difference. The second test was based on using steam traps to collect condensate on a rotary sterilizer run up to service temperature (240-260F). After the first step of collecting condensate from the back end of an uncoated canning shell, the thin insulation coated shell was run again to collect condensate. The cooled condensate volume from the two steps showed a 26% difference. Then standard steam tables were used to estimate cooling on steel surfaces of pipe. A 25% efficiency value was chosen from the two tests. That value was also supported by a saturated steam cost estimate generated by Bill Riker (attached). HOW THIN INSULATION COATING WORKS Radiation and Conduction-based Thermal Resistance Thin insulation coating relies on high density layers of low density ceramic micro-spheres in 10 mil (0.25mm) dry film thicknesses (DFT) and thin air gaps between those ayers of high density resistance. Typical thin insulation applications are 1mm to 2mm DFT and tested pull strengths of 280 to 360 psi. The high density layers of ceramic micro-beads block a broad spectrum of radiation-based heat transfer. Relatively thin layers of this coating are effective against solar heat loading on surfaces. low transmittance and radiation-based resistance to block heat transfer. Conventional low-density materials slow down heat transfer (conductivity-based) using their low-density mass. Thin insulation coating uses conductive heat transfer blocking. Low density mass ACS’s thin insulation’s K value for conductivity is 0.1176 W/mK using 0.75mm at 100C per a test lab. Typical applications use 1mm/80 mils to 2mm/80 mils dry film thickness (0.040” to 0.080"). A good thin coating example would be "Low E" windows' that use thin oxide layers that block infrared wavelength. A good analogy for low "transmittance" would be a ceramic coffee cup compared to a metal cup. The ceramic cup transmits less thermal energy than the metal cup. These two low heat transfer characteristics are very important in understanding how thin insulation coatings block radiant heat transfer. When comparing the two types of insulation, it's not that ceramic coating outperforms conventional materials. It's that conventional insulation typically fails due to moisture entrapment and cannot maintain rated value. And coating maintains its insulation value in wet environments. Conventional insulation is typically rated with tests conducted at 0% humidity at 70F. In the real world's 40%-90% relative humidity, material becomes saturated with moisture up to the level of surrounding air’s relative humidity. Insulation coating has a perm rating of less than 4, providing low acceptance of moisture and allowing retention of low heat transfer characteristics indefinitely. Thin insulation coating prevents corrosion under insulation (CUI) by preventing moisture contact with metal surfaces. Traditional material can't drive moisture out below 315 +/- Fahrenheit. Moisture entrapment is what generates CUI in traditional materials. Visual inspection of surfaces and equipment is also simplified, along with personnel protection. Thin insulation material cost is around $2/SF per 1mm/40 mils of thickness and can be applied using airless sprayer at 1000 - 1,500 square foot per hour or 8,000-12,000 SF per 8 hour day per airless sprayer. Lifespan of thin insulation coating to date has been 9-10 years in outdoor exposed applications and can be recoated. Food plant applications have a 1-2 season ROI. Rebates paid by PG&E or SoCal Gas ($1 per therm saved), provide $3,000+ per rotary sterilizer to food plants. Applications to date show 25% energy savings on saturated steam equipment, 33-37% energy savings on buildings based on monitoring energy use or removing AC equipment, 9% on heavy oil tank storage based on measuring gallons of heating oil used to maintain heat, 55% less energy to maintain heavy oil tank temperature in Hawaii, controlling condensation on ships operating in the Bering Sea and other locations around the world. Thanks for taking time to review this information.
