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Soundproofing is a specialism that revolves around effectively controlling unwanted noise, with various soundproofing materials used to mitigate the effects of noise.
Anything from people who want a quieter home and tranquility from noisy next door neighbours, to businesses who need to reduce the noise impact that they make on surrounding areas, soundproofing comes with a long list of causes and solutions.
In fact, there are a myriad of soundproofing materials that one can choose from to apply to different uses.
Some are more suitable or effective than others, which greatly depends on the type of noise created, the source of the noise, the structure of the building, wall construction, and various other key factors.
To understand soundproofing materials and how they perform, it is important to mention that sound is a form of energy.
Sound travels from a source, and during the distance that it travels it causes vibrations whenever it hits air and any objects in its path.
These sound waves then reach the recipient&#;s ears and stimulate the brain.
Soundproofing materials work to reduce the sound pressure created from the source to the receptor.
In this in-depth article, we&#;ll explore the 30 best known soundproofing materials in more detail, how they perform and where they are best used.
Soundproofing vs Sound AbsorptionBefore exploring soundproofing materials, it is advised to firstly understand the key differences between sound absorption and soundproofing.
It&#;s a common misconception to think that sound absorption is the same as soundproofing.
In reality they are not one and the same.
Sound absorption is in actual fact one element of sound proofing and is used in two ways:
Firstly, as part of a soundproofing system, as a material which is invariably added within a structure such as between the voids created in a stud wall, which can reverberate sound, adding sound absorption can prevent this.
Secondly, when sound absorbing materials are added to the surface of a wall or ceiling, it absorbs sound waves and reduces resonance and regeneration of the sound back into the room.
In doing so, improves the acoustics of a room which is called acoustic calibration.
For example, a noisy restaurant with hard surfaces typical of industrial influenced design of today&#;s trendy eateries, can result in a cacophony of sound from clattering cutlery and chattering diners.
This noise can be softened with panels of sound absorbing materials which equalize and balance the internal acoustics of a room which is acoustic calibration.
Hopefully this explanation is reasonably clear, but in a nutshell, sound &#;absorbing&#; materials reduce the resonance and reverberation of sound waves within a space or room.
Sound &#;proofing&#; materials prevent sound waves from passing in or out of the room.
Key Principles of SoundproofingSoundproofing is acoustic isolation &#; the prevention of sound waves passing in or out of a room.
In order to understand soundproofing or acoustic isolation, it is best to start by highlighting the key principles, namely:
DeflectionDeflection of sound is achieved by adding mass and density to any structure such as a wall, floor or ceiling.
All solid materials which have a thick consistency and are dense or somewhat heavy, can help to block sound.
By adding mass and dense materials between the source of the sound and the receiving point will offer additional bulk that the sound wave will have to pass through and in doing so will reduce its energy.
Increased mass and density of a wall &#;s construction can be achieved with concrete for example, or dense finishing boards such as ply, OSB, drywall or plasterboard.
Deflection with mass and density proves more effective with airborne sounds such as voices or music, and not so effective with impact noise such as foot fall, which is usually associated with stronger power, pressure and therefore vibration.
As sound waves strike the mass and dense materials, vibration will occur and in doing so will pass the energy from one side to the other through the materials&#; own rigidity.
This is the principle of flanking transmission noise &#; a common problem with all structural scenarios.
AbsorptionOpen cell woven types of material such as QuietFibre Stone Wool Cavity Insulation, which provides a soaking up or absorption of the acoustic energy entering it.
These are available in differing thicknesses and densities for an increasing effect and are usually installed in open cavities where the depth of material can be tolerated.
Not only do these types of absorptive materials offer absorption, but it is also important to know that by filling a cavity they can also prevent the potential of additional resonance, reverberation or amplification of sound waves that could be created if the cavity were to be left completely empty.
DecouplingThe principle of decoupling is to reduce the area of direct mechanical linkage between the substrate or structure, say for example of a wall, and the finishing materials.
This process is a way of interrupting sound vibrations or flanking transmissions that travel through the structures&#; own connectivity or rigidity from one side to the other.
This may well be by a complete decoupling of an internal structure such as what is commonly called a &#;room within a room&#; or a &#;cell within a cell&#; or may simply be a decoupling by counter battening or resilient channels.
A good example is the use of acoustic brackets, acoustic hangers or resilient channels, which will help to decouple drywall from the rest of the building&#;s structure.
As a result, the strength of the acoustic vibrations are reduced, thus slowing their potential passage through the wall.
Decoupling is best done during the construction phase of a building.
Thermal ConversionAcoustiblok Isolation Membrane is a material which works by converting sound energy into trace heat energy.
When sound waves come into contact with the membrane, it vibrates the molecules of the materials which in turn creates friction which is cleverly converted to a trace heat energy.
Thus the material works by converting a more problematic acoustic energy into a less problematic heat energy which is simply transferred through the material sideways to reduce flanking transmissions.
In any serious or advanced strategy to isolate sound, this is an absolute must to work in tandem with the other principles.
At only 3mm thick, the depth of the material is hardly noticeable in the grand scheme of things, but the benefits to uplift acoustic performance are immense.
The material has an optimum balance of mass and flexibility, however it does not rely only on its mass for acoustic performance, making it a unique and standalone sound proofing material.
Constrained Layer DampingConstrained layer damping is a principle of using specific materials in particular ratios to reduce the natural resonant frequencies of the structure, thus reducing the resulting flanking transmissions through from one side of the structure to the other.
Damping compounds are effective when applied between two rigid panels, such as drywall or plasterboard for example.
As a result, when the sound hits it, shearing forces between the panels creates friction in the damping layer and the sound ceases as it is converted to heat, in essence thermal conversion occurs.
This solution is ideal for low-frequency noises.
Key TakeawayThese essential principles of soundproofing outlined above work independently of each other, but can also complement one another.
Often, combining different methods by using two, three, four or more of these principles offers the best results.
Types of Soundproofing MaterialsThere&#;s an extensive list of soundproofing materials that you can choose from, for various applications.
Each of these materials has different best use scenarios, and they work by means of one or more of the soundproofing principles outlined above.
Let&#;s go over them in more detail to highlight key aspects of the material and how and when they are best used:
Acoustic Isolation MembraneThere are quite a few &#;acoustic membranes&#; on the marketplace, with some being better than others.
The most advanced membrane in this category is the unique Acoustiblok Isolation Membrane which is the thinnest and highest performing material available, mm for mm.
It is considerably lighter and enables a higher thermal conversion of energy from an acoustic energy into a less problematic heat energy and transfer through itself.
This material which is available in 3mm and 6mm thicknesses, is commonly installed within walls, ceilings and floors to mitigate airborne and impact sound.
Remarkably, it helps to block sound transfer more effectively than a sheet of lead and is ideal for sound insulation.
It is polymer-based and thus very flexible, adaptable and easy to install.
It offers effective acoustic insulation without increasing the thickness of walls or ceiling, or loading with excessive weight for example.
Some other materials are known as Mass Loaded Vinyl (MLV) which are simply a rubber compound impregnated to increase mass and density. These are much heavier materials and rely heavily on a deflective principle.
Open Cell Cavity InsulationThis material is typically installed into cavities, and tends to be made from rock wool,stone wool, mineral wool or fibreglass. QuietFibre is an example of a stone wool.
They are designed to fit snugly between wall studs, ceilings and floors and uses the principle of sound absorption.
By doing so they will effectively pack out the airspace usually found in these areas, and so the transmission of sounds are impeded or considerably reduced by their presence.
Decoupling ProductsBased on the principle of decoupling materials through which sound is transmitted.
The principle of decoupling comes into play here.
This material is used to decouple the main floor surface from the subfloor, and thus reduce noise transmission.
Common materials for acoustic flooring include Acoustiblok, rubber based crumb, cork and felt for example.
Soundproof WindowsSpecialist types of soundproof windows use the principle of decoupling to reduce the sound that enters or leaves a room where installed.
These windows typically have thick glass panes and a layer of air trapped in between each layer.
This is another type of architectural soundproofing solution.
Much like soundproof windows, soundproof doors are designed to use the principle of increased depth and mass as well as decoupling to reduce sound transmission.
Acoustic PanelsThese panels are another type of sound absorption board, commonly referred to as AcoustiCloud Panels and AcoustiWall Absorber Panels and are installed invariably on the surface or near the surface of ceilings and walls.
Again these are used more so for controlling internal acoustics to equalise and calibrate.
They are reasonably effective when positioned correctly and cover sufficient volume and surface area as well as being aesthetically pleasing on the eye.
Acoustic panels are seen as a decorative alternative to acoustic foam and come in a range of colours, shapes and designs.
Acoustic FabricsTypically used for theatre curtains, blackout curtains and studio blankets, acoustic fabrics are a very thick type of fabric which are effective when it comes to dealing with acoustics in large rooms or halls.
They are also used as a wall lining to increase acoustic equalisation within rooms such as cinemas.
Acoustic FoamAcoustic foam, also commonly known as Studio Foam, is wall mounted foam panels that can be flat, chamfered, convoluted, wedged or have pyramidal shapes protruding from them.
They mostly help to improve audio quality in studios and music rooms.
Acoustic foam works on the principle of sound absorption and re-calibration of internal acoustics, and so they are not as effective as other materials when it comes to blocking sound.
They should make a noticeable difference to internal acoustics and the audible values, but if you are looking for a sound blocking solution, there are far better materials you should consider.
It&#;s important to note that the thickness and densities of these foams vary, which in conjunction with correct positioning, plays a significant part in their effectiveness and performance.
You should also take into account the type and amount of surface area to be covered.
30 Best Soundproofing MaterialsSoundproofing materials come in all forms and kinds, as we have already outlined.
However, it is important to be aware of how and where they should be applied for best results.
Needless to say, it&#;s also important to consider the quality of the particular soundproofing material you intend to use to achieve the very best possible results.
Here&#;s a rundown of the 30 best soundproofing materials available on the marketplace and how best to use them:
1. Acoustic MembraneThere are different types of acoustic membrane on the market, some much heavier than others and some higher performing than others.
These will be rated by different dB reduction levels across differing Hz frequencies and are available in different thicknesses.
The thicknesses and weight will affect their application and effectiveness, so it&#;s important to choose well.
Mineral, rock or stone wool insulation, such as QuietFibre, are essentially open cell insulation materials which work very well at absorbing acoustic and thermal energies.
Invariably used in cavities such as stud walls, this rather rigid material comes in different thicknesses and densities and is used in both households and commercial projects as it is quite affordable.
Not only good at acoustic and thermal energy absorption but almost as important if not more so, it is very useful for filling cavities. This prevents the cavity from being an open and resonant &#;cave&#; like hole which can lead to an amplification of acoustic energy.
Despite being quite rigid, it is easy to cut.
Soundproof fibreglass comes in boards / slabs rather than rolls and can be used in various places and applications including to make acoustic panels in home studios, theatres and commercial buildings.
This soundproofing material is very effective in diminishing noise that enters or leaves a room, and also improves internal acoustics.
There are different types which you can choose from with differing thicknesses, densities and strengths.
For example 703 boards are best for reducing high frequency noises whilst 705 boards are more suited to low frequency bass noises.
Resilient sound channels are the main way of decoupling drywall from internal structures of buildings.
This system can also be installed with acoustic hangers or gaskets which further reduce the vibration.
Resilient sound channels are strips of metal or timber that are installed to the walls so that the soundproof insulation within the walls can be kept firmly in place, whilst providing a platform onto which all finishing systems can be attached.
This eliminates the direct contact that there would otherwise be through the layers of structure &#; walls, ceiling, floors.
Screws can pass through several holes or gaps found in these channels to ensure easier screwing, making them easy to install.
Any sounds that pass through will basically keep vibrating against the resilient sound channels, and so they are isolated from the room.
Sound isolation clips are designed to allow a decoupling separation between the walls and ceiling from the underlying framing studs and joists.
These moulded rubber and steel isolation clips are used to control sound and are designed to reduce vibration through a structure.
Apart from the common varieties of drywall which can be purchased at most DIY stores, there is also a more specialised form of drywall, namely soundproof drywall.
This comes in different thicknesses, and promotes having an increased sound transmission class than the other types of common drywall used in everyday construction, due to its increased density and mass.
Soundproof drywall typically combines several layers of gypsum boards, along with steel, with the main aim being to increase its density and mass so as to block sound effectively.
Having said that, any type of drywall can work well for soundproofing as long as decoupling is at the back of one&#;s mind.
To achieve good results in terms of soundproofing, it is important to choose thick drywall in conjunction with some other soundproofing methods, such as Acoustiblok 3mm Isolation Membrane, sealants, tapes and caulks for example.
OSB or Oriented Strand Board is a versatile and durable building board.
An alternative, plywood can be used as the construction is similar with multiple layers of opposing-oriented wood fibres that creates rigidity and strength with increased mass and density.
8. Soundproof Floor Underlay
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Floor underlayments are a great way to reduce sound transmission that naturally occurs between engineered floors and hardwoods.
There are different kinds of soundproof floor underlayment but felt underlayment is among the most popular options for floors of various kinds, including laminate floors, hardwood and engineered wood.
They are typically made from fibres which are compressed and treated with heat, so as to form a dense sound absorbing material.
A great example of this is Acoustiblok AcoustiWool Acoustic Underlay, which comes available in rolls and works best if installed in conjunction with Acoustiblok Isolation Membranes.
Soundproof floor mats are another interesting option to arrest impact sound and vibration leading to structural airborne noise.
It is a known fact that certain appliances and machines create a lot of vibration and noise.
Anti-vibration soundproof mats help to kill annoying humming sounds and vibrations.
These types of mats are effective at reducing noise, and since they eliminate vibration they are also ideal for installation beneath and inside machinery and appliances, as well as to soundproof cars.
They can also offer a level of acoustic absorption on a surface or within a room to help reduce unwanted regeneration/resonance and enhance high-end audio performance.
Acoustiblok Acoustical Sound Sealant is one of a number of well-known brands on the marketplace that is most renowned as a reliable soundproofing compound which works on the principle of decoupling..
It comes in dispensing tubes like sealant products, and so is very easy to apply.
This product is meant to be used as a sound dampening method that maintains Sound Transmission Class (STC) in applications where required, yet remains permanently flexible.
It is mostly used during the construction of walls that require soundproofing as it can be applied directly between layers of differing materials, Acoustiblok Isolation Membrane, drywall or plasterboard.
It works to dissipate sound vibrations that would otherwise manage to pass through walls.
Essentially this is a form of sealant that reduces leakage considerably and can be used on countersinking the heads of mechanical fixings.
A complementary soundproofing solution which is intended to seal overlaps of materials, fill small gaps, cracks, or spaces in a room.
Sound can travel through even the smallest areas, and so it is important to seal off a room completely for the best possible results.
Acoustic caulk is a must where plasterboard or drywall is installed to reduce possible weakness but should not be relied upon to achieve acoustic levels by themselves.
Areas like corners between walls, lines where walls and ceilings meet, and doors and windows must be completely sealed.
Flexible acoustic and intumescent putty is designed to maintain a building separation and wall partitions structural integrity and acoustic properties.
AcoustiPutty pads are designed to maintain the integrity and acoustic properties of flexible wall assemblies.
Like acoustic plasterboard, acoustic plaster finishes have been around for years.
Varying ingredients, compounds and systems can increase or decrease weight and flexibility to further reduce surface reflections and in doing so help with equalisation of the internal acoustics.
Soundproof or sound deadening spray is used mainly for spot treatments.
Floor mats for example, may have been installed to reduce unwanted noise yet microscopic gaps between the matt and the adjoining surface can still allow vibrations to occur.
Using a sound deadening spray will minimise those gaps and as such one would expect some improvement on overall acoustic performance, &#; the saying, &#;every little counts&#; could be applied here.
15. Soundproof Paint
Soundproof paint, sometimes also referred to as sound deadening paint, is exactly what it says on the tin!
As a paint it can be applied either by means of a roller or sprayed on.
The concept is that the thicker the layer of paint, the better the result.
Spraying will naturally lead to a thicker coating and so it is generally the recommended method of application for soundproof paint.
Having said that, soundproof paint is not the most effective soundproofing method and won&#;t produce significant results.
Due to its lack of mass once applied, the resulting soundproofing effects can be mixed.
Since it contains latex, similar to rubber, it is definitely better to apply rather than regular paint where breathability of the wall is not a concern.
Latex has a tendency to settle into cracks, just like silicone caulk, so will perform better than standard water-based paints, although again is non breathable.
Like soundproof paint, it is highly debatable whether soundproof wallpaper can effectively soundproof a room, especially when used in isolation.
Mass is one of the main principles of soundproofing, so it is difficult to have a thickness considered adequate by using just wallpaper.
Soundproof wallpaper is generally made from closed-cell polyethylene foam.
This has very good sound absorbing properties, so soundproof wallpaper can and should act like an acoustic absorbing layer but as it is so thin the effects are minimal at best but again the saying, &#;every little counts&#; could be applied.
Since soundproof wallpaper comes in an assortment of designs, it is obviously more aesthetically pleasing that acoustic foam, and much easier and less invasive to install.
Acoustic wall covering is a sheet material made from composite fabric layers.
A flexible hybrid composite that is strong, yet highly compressible and soft at the same time.
It is installed onto the internal surface of a wall to offer great results in acoustic calibration (softening) and acoustic isolation (conversion).
Worth mentioning that whatever approach one undertakes, it is only as effective as its weakest point.
Acoustically rated windows are specially designed windows that are ideal for soundproofing purposes.
Since these windows are constructed to include multiple layers of glass, with each being quite thick, the amount of sound that enters or leaves a room is minimal.
For improved results, such windows would incorporate air or inert gas, that is trapped in between each glazing panel to further effect movement of acoustic waves.
Soundproof windows are effective and they can even be installed right over the top of existing windows as necessary.
Once again it is worth mentioning that whatever approach one undertakes, it is only as effective as its weakest point.
Soundproof doors are of increased thickness, sturdy construction, designed to effectively block sound from entering or leaving a room.
Double door principles can also be a realistic method should the increased acoustic values and space be available to do so.
Well-fitting doors and frames with effective use of gaskets will of course be an important part to any success.
Such sound-blocking doors include rigid steel doors, solid-core doors, and other materials where mass is high, and their subsequent weight.
In such doors you will not find any openings like mail flaps or pet doors, because the emphasis on soundproofing cannot be minimised by making way for any gaps whatsoever.
Fire doors are a good example of soundproof doors.
Weatherstripping tape, door seals and sweeps are available in all sizes and are usually made from rubber and act as gaskets, similar to many draft stoppers.
These are attached to the door frame or bottom section of doors, in order to seal gaps between the door and door stop or frame, or door and the floor.
Rubber seals include hollow rubber weather-stripping tapes which compress whenever a door or window is shut, thus forming a tight seal.
Rubber sweeps tend to scrape against the floor whenever a door is open or closed and there are also sweeps which come in the form of a very dense brush.
Also a useful approach on an internal door can be to increase the size and thickness of the door stop or beading around the perimeter.
This increases the surface area of the door closing onto the door stop and can also increase the width of draft gasket that can be used.
Ideal for sound absorption, acoustic foam is available in a wide range of thicknesses as well as sizes and colours.
There are many brands names that sell acoustic foam.
Some even offer this material in appealing colours as some customers look for the aesthetic appeal of this product aside from its practical value.
Sound absorbers are available in many styles and types, most of which come in appealing colours.
When installed, they can also make a room or space look more visually appealing.
These types of Absorber Panel such as Acoustiblok Quiet-Cloud, AcoustiWall can be mounted to ceilings and to walls as it helps to cut down on acoustic reflections and sound reverberations.
That is why it is called sound &#;absorber&#; as it works on the principle of sound absorption.
Directly fitted to a ceiling or used as a structural drop ceiling to create a grid system, acoustic ceiling tiles are similar to acoustic panels to provide effective acoustic control.
Available in a wide variety of materials, sizes, depths and designs.
Acoustic ceiling tiles are an easy solution for improving the acoustical qualities of any space.
Soundproof curtains, sometimes referred to as blackout curtains or acoustic curtains, are widely used to reduce noise passage as a temporary partition or privacy material, such as backstage at a theatre.
When hung in strategic positions the thick fabric greatly reduces the spread and movement of sound waves within an area which reduces unwanted sound from travelling from space to space.
Soundproof blankets are used in various cases where sound absorption needs to be attained and offer a low-cost alternative to relatively expensive soundproofing solutions.
In fact, soundproof blankets are probably the most practical option for someone on a tight budget who wants a temporary and moveable solution.
They are made from thick, plush fabric which is designed to absorb sound and prevent acoustic transference.
Unsurprisingly, furniture and other household items can play an important role in soundproofing.
In some rooms, you might experience more sound reverberation than others.
This can be a nuisance yet funnily enough, can sometimes be resolved by simply moving your furniture to better sound dampening positions.
You could also try adding lining to walls, such as tapestries or fabrics, as well as make use of sofas and large soft cushions.
If specific walls are thin, it&#;s recommended you place heavy pieces of furniture against them, such as a wardrobe or a wooden bookcase full of books to dampen the sound.
Acoustic fencing is essentially an acoustic barrier or noise insulator for outside spaces.
It&#;s ideal for those who want an effective solution to block external sounds and noises.
Establishing correct height and length of fence is essential to create the necessary angles of incidence for maximum effect.
Acoustic fencing can tackle noise from road traffic, trains and railway tracks, and any noise from neighbouring plots.
Some fencing solutions will be as expected, constructed from thick, dense materials to work principally on mass and density to block line of sight.
These types of fence are great where a new structure has to be built although quite time consuming and expensive due to the amount of material and labour involved in their erection.
However, where a fence structure is already in evidence but not performing quite as well as one would like, there is also a material known as AcoustiFence.
This flexible membrane is designed to attach to an existing fence structure such as a post and rail or even chain link to increase performance.
Available in rolls of material and very easy to install with minimal labour offering a further saving on cost.
The material is essentially a membrane, and it can be hung or secured in place to post and rail, to lattice or attached to a timber frame, depending on the individual case.
Installation of soundproof fencing is fairly quick, easy and effortless.
As almost all regular absorber panels are compressible and work on the factor of absorption, they tend to also absorb and accumulate moisture which can create an issue when trying to use them externally.
Some materials though are hydrophobic.
An alternative to these is external acoustic absorbers which are a rigid, durable panel made from recycled glass beads with an appearance of a lightweight granite / stone.
Offering good resistance, they produce a sound absorbing, impact resistant panel solution which is not affected by liquid or moisture.
Also noncombustible, chemically inert and non-fibrous.
These acoustic panels are invariably manufactured from more industrial materials such as steel and aluminium to be employed to mitigate noise sources with higher power and pressure output.
Specifically designed to withstand outdoor exposure in full sunlight, extreme weather conditions, and harsh industrial environments (NRC of 1.0 is the highest sound absorption rating possible).
Examples like Acoustiblok All Weather Soundproof Panels are a triple core approach to include a perforated facia for diffusion, an internal layer of U.L. classified Acoustiblok 3mm Sound Isolation Membrane material for acoustic conversion plus a specifically engineered 50mm Acoustiblok QuietFibre hydrophobic/weather-proof, open cell, core sound absorbing material.
Typically, acoustic louvres are used in building openings permitting air to flow, whilst shielding the environment from unwanted noise.
As an open shutter with horizontal, curved or linear blades/slats that are angled to admit light and air, but to keep out rain and direct sunshine.
The angle of the slats may be adjustable
Through this article we&#;ve explained in great detail what soundproofing is, the various types of soundproofing methods and products available on the market.
We have also explained which products work best in different scenarios, according to one or more core soundproofing principles.
After this thorough overview, we hope that you have achieved a much clearer idea of this detailed subject.
If you are currently considering soundproofing your home, business premises, or perhaps a particular room such as a recording studio, home theatre or workshop, hopefully you can now make a well-informed decision on the best soundproofing method and materials to use.
Acoustiblok UK Ltd / Thermablok Aerogel Ltd gives no warranty and accepts no responsibility or liability for the accuracy or the completeness of the information and materials contained in this website, blog or media content. Under no circumstances will Acoustiblok UK Ltd / Thermablok Aerogel Ltd be held responsible or liable in any way for any claims, damages, losses, expenses, costs or liabilities whatsoever (including, without limitation, any direct or indirect damages for loss of profits, business interruption or loss of information) resulting or arising directly or indirectly from your use of or inability to use this website, material, content or any website linked to it, or from your reliance on the information and material on this website, even if Acoustiblok UK Ltd / Thermablok Aerogel Ltd has been advised of the possibility of such damages in advance.
SUCCESS STORIES share actual product applications using the strength of Insul-Fab's capabilities and supplier relationships to solve customer challenges.
The Situation
Recently, an air conditioning equipment manufacturing company in Texas submitted an inquiry for large rolls of OEM grade light-density fiberglass, a 1/2"-2" thick thermal insulation material commonly used in the HVAC and appliance market. The company intended to cut the rolls manually into various shapes for installation into air handling components.
The Solution
As both a distributor and a preferred converter of OEM insulation materials, InsulFab has the benefit of being able to supply fiberglass in rolls and sheets, or pre-cut parts. Since the application was price-sensitive, the customer perceived fabricated parts as more expensive, and wanted to know why a converted solution was more beneficial than buying rolls and cutting the parts in-house.
Raw Materials
Most engineered raw materials such as Johns Manville OEM Fiberglass Insulation and Lydall Thermal Insulation are made in large rolls or sheets. For the raw material supplier, manufacturing and shipping rolls in bulk offers efficiency in production, shipping and SKU management. Fabrication for end use is typically performed by a local converter or the end user themselves. For OEM applications with repeating shapes used in sustained production, there are many benefits to buying pre-cut parts.
Benefits of Fabricated Parts:
Precision cutting/tight tolerance fit
. Insulation fabcricators, like InsulFab, have experience and dedicated equipment for precision converting. By contrast, hand-cut parts vary by the skill level of the craftsman. In most instances, the parts simply do not fit well enough to install, leading to inconsistency in &#;stuffing&#; material into place or leaving voids with improper coverage..Optimum utilization of roll (preventing scrap and waste)
. Pre-cut parts can be nested through engineering programs to maximize the yield of the raw material, reducing scrap, which in turn saves on material cost. Hand-cutting can reduce material yield by 30% or more.Labor Savings
. Manual cutting is usually more inefficient than customers realize. For instance, die-cutting is a high-speed cutting method, and multi-cavity dies can produce a great number of parts with one impression. High-speed water jet cutting allows material to be cut in multiple layers, often five sheets or rolls deep, at extremely fast speeds.Smaller packaging
. Most rolls and sheets are difficult to unpack, handle and store, leading to potential damage and overuse of storage space. InsulFab neatly packages parts on poly bags of standard part count, for easy handling, storage and counting, which makes forecasting easier. Additionally, most bags are vacuum packed, further reducing their profile and making shelf storage and point-of-use easyValue Add
. Die-cut or fabricated parts provide additional opportunities for value additions to the material, such as foil/scrim/kraft (FSK) facing lamination, anti-microbial edge treatment, or addition of pressure sensitive adhesives.Fortunately, in this instance, Insul-Fab was able to demonstrate the value that each of these benefits would bring to the customer. After considering each of these benefits, the customer was persuaded mostly by InsulFab&#;s ability to save them space and provide an easier inventory count for planning and forecasting purposes. When considering in-house manufacturing, it is always best to at least consider all of the benefits to a converted solution, even if in the end, in-house fabrication remains the best option.
Date/Pub ID: 11/4/ SS018
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