Energy efficiency in industrial plants

Industrial energy costs continue to rise and CO₂ reduction requirements are becoming more stringent. Companies are looking for solutions to reduce their bills and meet Green Deal standards. One of the most effective yet underestimated tools is proper technical insulation.
In this article, we will show how industrial insulation affects energy consumption, what savings it offers and why training new fitters is becoming a strategic activity for industry today.

How does insulation affect energy costs?

• The insulation reduces heat loss by up to 90%.
• Every uninsulated valve, elbow or pipeline represents a real financial loss.
• Example: an uninsulated DN100 valve in a steam system can generate losses of up to several hundred euros per year.
• At the scale of an industrial plant, this amounts to tens and sometimes hundreds of thousands of euros „escaping” through lack of insulation.

Impact of insulation on CO₂ emissions

• Less energy consumption = less greenhouse gas emissions.
• According to reports by the EiiF (European Industrial Insulation Foundation), in Europe alone, emissions equivalent to ... the annual energy production of a medium-sized country could be avoided through proper insulation.
• For companies, it is not only about going green, but also about meeting EU regulations and ESG reporting requirements.

The most common areas of energy loss in plants

1. Valves and fittings - difficult to insulate but generate the greatest losses.
2. Elbows and reductions - leaking or poorly constructed insulation causes energy to escape.
3. Boxes and oflachunks - often ignored, and responsible for a high percentage of losses.
4. Damaged insulation - lack of maintenance and inspection reduces insulation effectiveness.

Return on investment (ROI) in insulation

• The cost of proper insulation pays for itself within a few months to 2-3 years.
• TIPCHECK (EiiF) audits show that investment in insulation is one of the fastest paybacks in the industry.
• Companies report energy savings of 20-40% after comprehensive insulation upgrades.

The role of training in ensuring energy efficiency

• No vocational schools → professionals are prepared only by specialised training centres such as Natalux.
• Ageing workforce → industry urgently needs new employees.
• Standards and ESG → fitters must be familiar with international standards (NORSOK, CINI, PN-B).
• Subsidies → thanks to BUR and EU funds, companies can train employees with a minimum contribution.

Technical insulation is one of the simplest and most cost-effective tools for reducing energy costs and CO₂ emissions. Companies that invest in proper insulation installation and employee training gain not only financially, but also in terms of image - demonstrating that they are meeting Green Deal and ESG targets.