Case study: how companies have reduced energy costs and CO₂ emissions through insulation and employee training.

The figures speak for themselves. Every uninsulated valve, every metre of pipeline without proper insulation is a real waste of money and CO₂ emissions. Companies across Europe are increasingly investing in upgrading their insulation and in training their own staff - because these are the measures that pay off most quickly.
In this article, we provide examples from Natalux's energy audits and training experience that show that well-made insulation = quick return on investment.

Example 1 - Chemical plant in Germany

• The TIPCHECK audit found that uninsulated valves and elbows were responsible for more than 25% of energy loss in the steam plant.
• After a comprehensive insulation upgrade, losses fell by 80% and annual energy savings were the equivalent of €350,000.
• Payback time: 9 months.

Example 2 - Refinery in Norway

• The company commissioned an audit and staff training on NORSOK M-004 standards.
• The students, who had previously worked as fitters without certification, began to use correct box and oflachunk insulation techniques after the course.
• The result: improved assembly quality, fewer complaints and failures, by 30% less inspection time for acceptance.

Example 3 - Polish thermal power plant

• During the insulation audit, significant losses were discovered on uninsulated pipelines in high-temperature zones.
• After staff training and insulation upgrades using high-temperature materials (PyroGel, ceramic wool):
  • reduction in energy loss by 70%,
  • Improved occupational safety - 60% decrease in burn claims,
  • the ability to demonstrate real environmental performance in ESG reports.

The role of training in achieving these effects

• The staff must be prepared. Even the best insulation material will not do its job if it is poorly installed.
• Natalux training courses teach:
  • precision assembly in accordance with NORSOK, PN-B and CINI standards,
  • calculation of ROI and energy balance of insulation,
  • recognise assembly errors and their impact on efficiency.
• By being listed in the Development Services Database (BUR), training can be funded by EU and national programmes - making it even more cost-effective.

Summary

Each of the above examples shows that industrial insulation is not a cost, but an investment with one of the fastest returns on the market. Companies that combine insulation modernisation with professional training of their staff gain doubly:

• save on energy bills,
• improve safety and quality of work,
• build competitive advantage by meeting Green Deal and ESG requirements.