CASE STUDY
XPS INSULATION MANUFACTURER TRANSITION TO LOW GWP BLOWING AGENT
Executive Summary
An XPS insulation manufacturer required a replacement for HCFC-142b following EPA phaseout regulations related to global warming potential and ozone depletion.
After evaluating multiple alternatives, the manufacturer implemented an Ecomate®-based blowing agent blend. The solution enabled a 67% reduction in product GWP while improving thermal performance and maintaining existing production costs.
The transition also delivered significant environmental impact reduction, eliminating more than 430,000 metric tons of CO2 equivalent annually.
Project Snapshot
APPLICATION
Extruded polystyrene (XPS) rigid foam insulation boards
PRIMARY OBJECTIVE
Replace HCFC-142b with a compliant, low environmental impact blowing agent without compromising performance or cost
KEY OUTCOMES
- 67% reduction in GWP
- Improved thermal insulation performance
- No increase in manufacturing cost
The Production Challenge
The manufacturer needed to transition away from HCFC-142b due to regulatory requirements tied to ozone depletion potential and global warming impact.
Key technical requirements included:
- Maintain or improve thermal performance (R-value and K-factor)
- Preserve closed-cell structure and moisture resistance
- Avoid increases in raw material or processing costs
- Ensure compliance with EPA SNAP regulations
Identifying a solution that met all criteria without disrupting production was critical.
The FSI Solution
FSI supported the manufacturer in evaluating and implementing an optimized blowing agent formulation incorporating Ecomate®.
FSI’s Ecomate® blowing agent technology is
- PFAS-free
- Zero ODP
- Zero GWP
- VOC exempt
- EPA SNAP approved
Through formulation development and validation, the new blend was successfully integrated into existing production processes without requiring capital changes.
Results
The transition to an Ecomate® blend delivered measurable performance and sustainability gains:
Environmental Impact
- 67% reduction in product GWP
- Elimination of over 430,000 metric tons of CO2 equivalent annually
- Equivalent to removing more than 90,000 passenger vehicles from the road
- Comparable to emissions from electricity use in over 59,000 homes
Thermal Performance
As shown in the performance charts on page 2, the Ecomate®-based XPS boards outperformed competitive materials in both:
- R-value across temperature ranges
- K-factor efficiency
Operational Impact
- No increase in manufacturing cost
- No disruption to existing production processes
Customer Outcome
The manufacturer successfully transitioned to a compliant, low-impact blowing agent system while strengthening product performance.
Key outcomes included:
- Enhanced insulation efficiency for end users
- Reduced environmental footprint across product lifecycle
- Maintained cost competitiveness in the market
End users benefit from improved energy efficiency in buildings and refrigeration systems, resulting in lower long-term heating and cooling costs.
Ecomate® enabled a balanced solution across sustainability, performance, and cost.
By aligning regulatory compliance with measurable product improvements, the manufacturer achieved a stable transition with immediate environmental and commercial benefits.
SERVICE WHAT WE SELL
Responsive Technical Support
FSI stands out for its unmatched customer support and industry expertise. We’ve helped businesses launch foaming operations, engineered specialized foam systems to tackle complex challenges, and provided continuous on-site service to ensure optimal performance.
- Routine on-site services
- Production demo, trial, and implementation
- Process consultation
- Custom formulations
Global reach.
Tailored support.
FSI serves manufacturers on an international scale with a sales, production and distribution network that spans the globe.
