False Information about Extruded Polystyrene

Recently, there has been a document circulating in the industry that has a lot of misinformation concerning the use of extruded polystyrene insulation and its compliance with the Energy Independence Security Act of 2007.

We normally ignore incorrect information that is generated with the sole purpose of discrediting a competitor but the severity of this document begs to be clarified.

The document can be found by clicking the pdf icon.

First, there are presently two types of foam insulations being used in the manufacture of walk-in coolers and freezers in the United States.  These insulations are Extruded Polystyrene and Foamed –in –Place Polyurethane insulation.  Many companies in North America have the ability to use both types of these insulations.  Both insulations have benefits that can be used to provide a quality walk-in cooler or freezer. Companies that use both types of insulation can apply each of these insulations in parts of a walk-in that they perform best and therefore bring the best designed quality walk-in cooler or freezer to the marketplace.  Some companies do not have the capability and therefore turn to attacking the insulations they do not have the ability to use with misleading information to compensate for this deficiency.   This situation seems to be one of them.  There are six points that need to be addressed. Read the rest of this entry »

Zero Ozone-Depleting FOAMULAR Extruded Polystyrene Insulation

Toledo, Ohio – Owens Corning (NYSE: OC), a global leader in building materials and energy efficiency solutions, today announced it has started manufacturing zero ozone-depleting FOAMULAR^® Extruded Polystyrene (XPS) rigid foam insulation. The new blowing agent technology developed by Owens Corning meets the requirements of the Montreal Protocol which requires the phase-out of the hydrochloro-fluorocarbon (HCFC) 142b, an ozone-depleting compound, by January 1, 2010.

Owens Corning’s new Gresham plant is the first facility in the Western U.S. to meet the requirements of the Montreal Protocol and expands the company’s XPS foam production capabilities. The company also has converted its Rockford, Ill., insulation plant to use the new blowing agent, and all FOAMULAR products will meet the requirements of the conversion deadline.

“High performance homes and buildings are an ever-growing segment of the construction industry, and Read the rest of this entry »

A Matter of Insulation: Acquisition vs. Lifetime Savings

Your cold storage equipment may be one of the most important choices you make. A significant amount of costs are associated with your walk-in. Before you purchase, make sure you consider the entire lifecycle of the walk-in instead of just the acquisition price.

The two main elements that effect energy and cost savings while running a walk-in are the refrigeration and insulation.  To get the optimal results from your refrigeration it must be sized correctly taking in consideration the size of box, if it is a cooler or freezer, and what will be stored inside. (There are many other factors that are considered when sizing refrigeration.) Insulation is the key to energy savings because it is responsible for holding the cool temperature in the box so the refrigeration does not have to work overtime. Insulation quality is measured by R-value; the resistance to heat flow through an object. Since EISA was implemented January 1, 2009, all walk-in manufactures are required to have an R-value of R-25 for coolers and R-32 for freezers. Now that all manufacturers follow the same requirements, the performance of the insulation is what differentiates the walk-in.

The two common types of insulation used are polyurethane and extruded polystyrene.  Each type of insulation brings with it strengths and weaknesses that must be evaluated for each individual application.

U.S. Cooler uses both insulations. Through experience and research, U.S. Cooler believes extruded polystyrene is the best insulation for the walls, ceiling, and floors of coolers and freezers. Polyurethane is better to insulate the doors of their walk-ins. According to a study performed by the U.S. Corps of Engineers, they found that over a five year period extruded polystyrene retains 75% of its R-value while polyurethane retains 25%.¹  This is one reason why U.S. Cooler believes extruded polystyrene provides the most value and the best option for walk-in insulation.

Polyurethane & Extruded Polystyrene

Read the rest of this entry »

Cooler Insulation- Extruded Polystyrene Vs. Polyurethane

U.S. Cooler uses Extruded Polystyrene as their insulation in their walk-in coolers and freezers. Polystyrene has many characteristics that prove it to be the best insulation material for walk-ins. The two main insulations found in walk-ins are Extruded Polystyrene and Polyurethane. Each insulation has differentiating characteristics and should be optimized for the specific application.

Polystyrene is a dense closed-cell structure that is very resistant to moisture and holds its R-Value longer than other competing insulations found in walk-ins, such as Polyurethane. This allows less water infiltration in the insulation, which in turn saves energy and money. When water starts seeping into the insulation’s pores, the R-value drops dramatically causing the refrigeration to work harder to hold its respective temperature. Refrigeration working overtime means higher energy bills. Polystyrene is less water vapor permeable; therefore, water vapor does not infiltrate through the material as quickly or easily as it does other insulations. Using studies performed by the U.S. Army Corps of Engineers (CRREL), U.S. Cooler demonstrated extruded polystyrene saved consumers over $5,000 in energy costs over the first five years of operation. The savings again are due to extruded polystyrene’s ability to resist moisture and to retain its R-value better than other insulators.

Polystyrene used in walk-in coolers and freezers is made from “at least 20% pre-consumer recycled polystyrene.” (Owens Corning, Technical Bulletin: Recycle Content Claims Must be Reliable and Verifiable) Polystyrene found in walk-ins is also 100% recyclable. Manufacturing companies that produce these insulation materials, reproduce the resources in new insulation material. Alternatively, it is important to note that Polyurethane is produced from chemicals and is not made from any recycled materials nor can it be recycled or reused.

Polystyrene in walk-in coolers and freezers is the most cost effective and environmentally friendly insulation used in walk-ins today. Not only is polystyrene in walk-ins made with recycled materials and is 100% recyclable but it is energy efficient and can save a great deal of money in energy costs and reduce carbon footprint over the life-cycle of the walk-in.

New Hybrid Panels

U.S. Cooler introduces New Green Hybrid Walk-in Coolers

Quincy, IL, December 23, 2008–U.S. Cooler is introducing their new green Hybrid panels for walk-in coolers.  U.S. Cooler’s new product launch will be January 1, 2009. The Hybrid panel is a 4” thick panel, consisting of 3” Extruded Polystyrene and 1” Expanded Polystyrene, which exceeds EISA requirements.  This combination provides the customer with the strength and moisture resistance of Extruded Polystyrene and the insulation economics of Expanded Polystyrene.  With these crucial characteristics, the Hybrid is the best designed and engineered competitively priced panel in the market.  U.S. Cooler will offer the Hybrid cooler in addition to their leading line of 4” Extruded Polystyrene coolers and freezers.  Unlike Polyurethane walk-in manufacturers, U.S. Cooler’s panels are 100% recyclable and are made from over 60% recycled materials.

When purchasing a new walk-in cooler or freezer, the initial cost of the walk-in is almost always the deciding factor. With U.S. Cooler’s new Hybrid Cooler you will receive a high-quality box at a reduced price. In addition to the up-front cost savings, the Hybrid will also save you money over the lifecycle of your walk-in. The Hybrid cooler is ideal for the customer that wants the most efficient and competitively priced walk-in cooler in the industry. Its overall product lifecycle cost will prove that this walk-in is one of the best walk-in coolers available.

The goal of U.S. Cooler’s high quality walk-ins is to obtain and maintain the highest possible R-value, ultimately resulting in energy and cost savings. Both Expanded and Extruded Polystyrene are a closed-cell structure that is free of voids preventing both air and moisture infiltration which allows it to sustain a high thermal opposition through the life of the walk-in.

Congress passed the Energy Independence and Security Act of 2007 to help reduce energy consumption in the United States. The Act requires commercial walk-in coolers and freezers under 3,000 square feet to contain an insulation R-value of at least R-25 for coolers and R-32 for freezers. U.S. Cooler’s products exceed the government requirements. U.S. Cooler’s new Hybrid cooler has an R-value of 25.8 while their freezers have an R-value of 32.4, both exceeding government standards.

Our New Hybrid Insulation

You can also read about the differences between extruded polystyrene and polyurethane.