Production of foam insulation business plan

Are you considering launching a company that produces foam insulation? You are entering a world where creativity and necessity coexist. Energy efficiency is becoming increasingly important to both businesses and homeowners in the environmentally conscious era. A good option that offers both sustainability advantages and efficient insulation is foam insulation. A business plan for the production of foam insulation must combine market research, strategic planning, and technical knowledge.

Priority one should be given to comprehending the product. Spray foam, rigid foam boards, and foam-in-place insulation are some of the different forms that foam insulation can take. Every variety has special qualities and uses of its own. For example, spray foam expands when applied, filling in spaces and forming a smooth barrier that blocks heat transfer. Conversely, rigid foam boards provide excellent insulation value while requiring little thickness. In order to customize your production line to satisfy market demands, it is essential to understand the advantages and disadvantages of each type.

An important factor in creating your business plan is market analysis. Who are the clients you hope to attract? What are their problems and needs? Your product offerings and marketing strategies can be more effectively tailored if you are aware of the preferences and demographics of your target market. It’s also critical to keep up with industry developments and laws. Eco-friendly insulation solutions are in greater demand as environmental concerns and energy codes become more stringent.

Creating a solid production strategy is also essential to guaranteeing effectiveness and quality. This covers every aspect, from locating raw materials to streamlining production procedures. You can improve the performance and consistency of your products by investing in state-of-the-art equipment and choosing reputable suppliers for your foam ingredients. Enforcing quality control procedures at all production stages protects against errors and disgruntled customers.

Last but not least, a thorough business plan includes risk-reduction tactics and financial estimates. What is the required capital to establish the production facility? Which costs, like labor and utilities, are constant? Performing comprehensive cost-benefit analyses enables you to determine whether your business idea is feasible and to obtain funding from lenders or investors. Furthermore, by recognizing possible risks, like shifts in the cost of raw materials or modifications to regulations, you can create backup plans and protect your company from unanticipated difficulties.

Assembly of the unit guide for beginners

Once you’ve made the decision to build your own foam generator, be sure to buy the necessary supplies and equipment beforehand:

• metal sheets;
• hoses;
• pipe;
• welding;
• pump;
• compressor;
• adjustable valves as well as their shut-off counterparts.

A jig washer can be used to replace the nozzle.

The first thing to do is to assemble the vessel into which the concrete mixture and air will be supplied in the required proportions. For a tank for this purpose is perfectly suitable for any iron container, the shape of which is close to cylindrical. In order to ensure a continuous supply of raw materials to the machine, a submersible pump and a hose must be installed. Another hose will supply compressed air to the foam generator structure. With the help of a special valve it will be possible to adjust the pressure inside the structure. For example, if you want to increase the pressure level in the foam generator, the valve must be closed off.

Rudimentary foam generator drawing

Typically, the Laval nozzle is installed independently within the unit housing. Additionally, the channel, which will occasionally be expanded and clamped, should be included in the design.

Although foam patron is the system’s final component, its existence isn’t really the most crucial aspect of the whole building. The reason for this is that foaming occurs precisely in it.

Hedgehogs or nets, which are the most popular dishwashing tools, must be placed inside the foam patron in order to produce foam. Expertly drawn drawings precisely depict the kinds of connections within the design and the placement of its constituent parts.

On what principle the plant works

Experts in the modern era have worked to create the most straightforward technology for putting this equipment together at home. To assemble a dependable and high-quality unit, one must comprehend the underlying principle. In actuality, foam is produced with the aid of this apparatus, and foam concrete is built upon that foundation. Traditionally, the production unit is made up of three distinct modules that work together to guarantee the system’s seamless operation and the machine’s ability to perform its primary duties. It concerns:

• modules that produce foam, and also carries out its transportation. With this module it is possible to produce foam;
• control element, by means of which automated dosing of the product is provided.

Component ratios for the concrete mix

Pre-prepared concrete solution is introduced into the foam generator, where it is converted into foam concrete and pre-mixed with air under the influence of a specific pressure. Experience has shown that this kind of equipment can be highly productive and reasonably priced. Therefore, it is entirely feasible to construct a machine that can generate roughly 500 liters of material per minute.

You can use your hands to make a concrete mixer, a tool that goes along with this machine, for the foam generator. But you can also buy it in advance at the store. Additionally, a regular shovel or other easily handled instrument made for manually mixing mixtures can easily take the place of a concrete mixer in certain situations. In one way or another, the purpose of the concrete mixer is to create the mixture—that is, to combine the material’s aforementioned components.

The unit produces foamed concrete continuously.

Preparation of HLW

To get ready, you’ll need:

• check the correctness of hose connections to the component parts of the installation, the integrity of the electrical wiring;
• connect to the installation sources of compressed air and electricity;
• containers B2 and B3 to connect each other and connect to the HLW according to the structural diagram directly to the suction connection of the pump feeding solution PENA flexible hoses with an internal diameter of 12 mm;
• Resin container B1 is connected to the plant directly to the suction connection of the resin pump with a 25 mm diameter flexible hose.

At least 0.5 meters should separate the foam and resin connections of the installation from the height of the drain connections of vessels B1–B3. Making the 4% foaming agent solution:

• 0,1 liter of PO is used for 1 m3, if in a shift to produce 20 cubes of foam insulation, it is necessary to prepare 2 liters of PO and dilute it with water 1:24 to obtain a 4% solution, i.e. е. 48 liters of water;
• 4% solution of ABSC (PO) is prepared in hermetically sealed containers made of polyethylene or stainless steel;
• Concentrated ABSC 2 liters is diluted in 48 liters of hot water (70-80 °C) and stirred for 5-8 min. Until a homogeneous transparent light brown liquid is obtained.

Getting the foam solution ready:

• take 500 ml of 85% orthophosphoric acid;
• Pour into a plastic container (50 l.) 45 liters of water heated to 40 °C;
• Into the heated water pour the KO and stir;
• Pour 5 liters into the prepared solution. the previously prepared 4% PO solution and mix thoroughly for several minutes.

Enough Foam is left over to create 2 cubic meters of foam insulation with a density of 15 kg/m3. Filling the molds with the foam mass:

• Pour into containers B1 and B2 solutions of resin and foam;
• open the valve of the supply to the installation of the solution PENA;
• Open for 2-3 minutes the valve КР4 on the upper panel of the installation to supply the PENA solution to the working part of the electric pump H₂.

The transparent hose allows for visual monitoring of the filling process. Turn on the valve that supplies the plant with the mortar solution.

• open for 2-3 minutes the tap КР5 on the upper panel of the unit to supply the CMOL solution into the working part of the electric pump H1, visually watching the filling.
• switch on briefly (3-5 sec) both electric pumps and make sure that they work according to the readings of manometers (manometer "SMOLA" should show more than 0.4 MPa (4 kgf/cm2), manometer "Foam" more than 0.3 MPa);
• after making sure that the pumps are working properly and the connections are tight, turn off the electric pumps;
• turn on the source of compressed air (compressor) and make sure it is supplied by the air coming out of the outlet hose;
• turn on both pumps and start pouring the foam mass into the molds.

The plant can be shut down for brief periods of time (up to five minutes) by turning off the electric pumps that supply the resin and foam solutions and cutting off the air supply. This takes place:

• for 10 min. before the end of work pour hot water (45-50 degrees Celsius) into tank B3 for rinsing (at least 30 liters of hot water is necessary for rinsing);
• after making a decision to stop the work, it is necessary to open the valve KR3 of water supply to the unit;
• as soon as the water flows through the SMOLA supply line close the valve KR1 of the SMOLA solution supply to the plant.

For five to ten minutes, flush the resin line and outlet hose. For three to five minutes, rinse the PENA line. It is advised to slice urea foam into slabs that are at least 4 cm and no more than 20 cm thick. The waste that is produced while cutting is placed in a different container. The container is sent to dry after it has been filled. For two to three days, cut foam boards are stored in the drying area on shelves.

According to TU "Unipor crushed," the dried waste is crushed. For future sales, the crumb is packaged in polyethylene bags. Foam boards that are completed and polyethylene bags filled with crumbs are kept in the finished product warehouse until they are needed.

In the video: Foam insulation production installation

Composition and application

Urea resin is a polymer and the primary ingredient in foam insulation.

The following is used in the creation of foam insulation:

• polymeric urea resin;
• hardener
• foaming agent;
• water specially prepared for the process.

The foam insulation looks a lot like a soufflé when it’s finished. It solidifies when it comes into contact with air, filling in the spaces between the building’s structural elements and insulating the space from noise and heat.

Foam insulation can be produced using currently available machinery or assembled by hand in accordance with drawings. Because foam insulation is easy to use, you can use it year-round without being reliant on the weather. Partitions, floors, walls, foundations, and roofs can all be insulated with this material.

You can prepare the insulation material at home because the manufacturing process isn’t too tough. Producing foam insulation with your hands is a real challenge if you don’t have much experience in construction, don’t have the necessary knowledge, and don’t install it well.

The following items are used in the foamizol production process:

• mortar pump;
• foam pump;
• foam generator;
• compressor;
• power supply.

Foam insulation can be produced indoors for sale to outside businesses or consumers, but using a foam generator to produce the insulation directly on the construction site will save transportation costs.

Several manufacturers are present on the contemporary market offering equipment for producing foam insulation. A wide range of Russian and Ukrainian equipment (Pena-2000 DMU, Pena-2000 10/UM, Pena-2000R) is presented to the entrepreneur who made the decision to start producing foamisol.

Unit of foam insulation Foam 2000 DMU

It is imperative to ascertain promptly for what purpose the installation is being purchased. It’s not essential to buy pricey equipment if you intend to insulate your house and a few items for your family and friends; instead, aim to stay within a tight budget.

You have the option to create a gas-liquid or pneumohydraulic installation on your own.

Check out this article about using foam insulation to insulate your home.

Nuances of assembly work

No device assembly variant exists that does not presuppose the existence of specific features. The independent manufacture of equipment for the production of building materials has very important specifics because of the peculiarities of the construction industry. Thus, in response to the query of how to construct a foam generator by hand, they refer to the following specifications:

• The input diameter of the nozzle and its depth should be no more than thirty millimeters and correlate in the proportion of one to one;
• The ratio of three to one is suitable for the ratio of the Lamal nozzle depth to its outlet diameter;
• The central hole in diameter should be ten millimeters.

In addition to being needed for building, foam generators are also required for homes.

It is important to remember that selecting the right foam cartridge dimensions is essential if you want to maximize the equipment’s productivity to about 200 liters per minute. As a result, its diameter should range between 30 and 40 millimeters, and its length is constrained by indicators between 600 and 800 minimeters.

A foam generator that is put together correctly will endure a long time.

Special attention is worthy of foam patron. For its manufacture, it is worth choosing a wire mesh rather than a spiral-shaped one. With regard to the filling, it is worth favoring stacks made of stainless steel. They, as well as a filter for the exit of foam from the structure, can be bought in an ordinary store in advance. The body of the foam patron should be tightly filled with meshes, and on its output to install a ruff with a washer. It is also possible not to install a ruffle, but in this case splashing of the product at the outlet of the construction will not be avoided. In addition, it will not best affect the operational life of the entire structure. Assembly of the foam generator, provided the theoretical savvy of the average level will not be difficult, and the resulting unit will serve for a long time and qualitatively.

Ready-to-use foam concrete is filled molds.

Important characteristics of the insulator

It should be recognized that the apparatus’s quality will be influenced by the final product’s quality. Additionally, the following crucial elements of foam insulation should be mentioned:

1. Ease of assembly before you start work. Must be easy to use.
2. The level of performance should be very high.
3. Mixing of components should be accompanied by high quality.
4. It should be possible to adjust the basic parameters.
5. The equipment should be characterized by compactness, mobility, light weight.
6. There should be high wear resistance.

Principle of action

The primary purpose of the foam generator is to supply foam to the previously prepared cement mortar and sand.

To make foam concrete, a standard concrete mixer is utilized. It is used to combine mortar for bricklaying or concrete for pouring walls and foundations.

Ordinary concrete becomes foam concrete when a specific amount of foam falls into it during the mortar-mixing process.

All experts are aware of the benefits and drawbacks of foam concrete. These days, this construction material can be ready right where the house, garage, or other structure is being constructed.

Foam generator structure

Before you begin building a foam generator by hand, you must maximize every illustration and description that has come to light.

The truth is that a lot of experts put their newly acquired knowledge into practice right away after becoming familiar with the foam generator’s working principle.

Plans and illustrations:

Every car wash has a clear demonstration of the foam generator.

Here, the generator is used to spray washing foam onto the car body. It also "gasses" foam blocks during the process of creating foam concrete.

A portion of the concrete block is filled with foam during mixing, which lowers the block’s initial density.

The following components can be combined to create the most basic foam generator:

• foam solution feeding spigot;
• compressed air supply nozzle;
• mixing chamber;
• foam patron.

Building material stores always have factory-made foaming agent on their racks.

If such a chance does not arise, the emulsion can be made by combining bone carpenter’s glue, caustic soda, and oleoresin rosin. Though not difficult, preparation calls for attention.

Once the DIY foam generator is assembled, it is necessary to inspect its quality. There needs to be enough density and resistance in the foam.

Assembly and connection

The mixing chamber and the foam patron are the two primary components of the foam generator used to produce foam concrete.

In this particular context, it is imperative to underscore that these terms conceal elements that are commonplace and recognizable to artisans.

An ordinary pipe serves as the mixing chamber. The future generator’s power is taken into consideration when selecting the pipe’s diameter. The pipe has two nozzles welded to it.

The first is at the end and is intended for air supply, while the second is 90-degree angled in the middle of the pipe. The blowing agent solution is supplied through it. Every pipe needs to have a shut-off valve installed on it.

Two valves are installed on factory-made foam generators for foam concrete: a regulating valve and a shut-off valve.

Recent experience has demonstrated that one shut-off valve is sufficient for small-scale production needs, such as making foam blocks for building a garage or summer house.

A pipe is welded to the second end of the mixing chamber to serve as the foaming chamber. The spigot’s inner surface is processed in the shape of a funnel whenever at all possible.

In order to guarantee that foam forms, this is done to lower the flow rate of the blowing agent and air mixture.

Some nuances

An apparatus called a gizzard or a Laval nozzle is fixed between the mixing chamber and the foam chamber when they are connected.

The purpose of these components is to accelerate the mixture’s flow from the chamber to the foam patron. The final stage of foam formation happens inside the foamatron.

A specialized filter "brothers" the blowing agent’s flow to increase process efficiency.

Use kitchen metal nets, available at any hardware store, as a filter in DIY foam generators.

It is not hard to construct a foam generator by hand in order to produce foam concrete. Understanding the generator’s operating principle is crucial in this situation.

Making the correct connections between the foam generator and the main equipment is the technically more challenging task.

There are currently many different designs for concrete mixers, which are used to produce blocks.

It is important to identify every installation component that is used to connect pipes and hoses before assembling the foam generator.

RAW MATERIALS FOR FOAM INSULATION

PENOISOL components are widely available and produced by numerous chemical industry enterprises in Russia and the Commonwealth of Independent States.

Resin for foam insulation.

Only the resin VPS-G is used to make PENOISOL, the foam plastic itself. However, any other polymer resin can be used; however, the foam cannot be referred to as FOAM INSULATION. We utilize KFMT-15 resin, which is made throughout Russia.

The plants and cities that produce KFMT-15 resin, which is the preferred material for making foam insulation, are listed below:

• Yaroslavl JSC "Lakokraska" g. Yaroslavl.For questions on purchasing please contact
  to the sales department (0852) 25-26-55, 27-06-12, 27-06-57 to Batagova Larisa
  Alexandrovna.
• Donetsk SGPP "Association Azot" Tel. (06452) 92141, sales department.
  Contact person: Sokolov Sergey Anatolievich
  Phone: 3832 34-11-00 Fax: 3832 34-11-00Krasnoyarsk
  Address:
  660004, Moscow, Russia, Sverdlovsk region. Krasnoyarsk, ul. 26 Bakinskikh commissarov, 1
  E-mail: pkchimen@online.ru
  General Director: Victor Sergeyevich Goncharov
  Chief Engineer: Anatoly Vinokurov
• Moscow E-mail: dsp@plitadsp.ru
  Address: 109202, Moscow, ul. 1-ya Karacharovskaya, house 8 (DOK-3).Orekhovo-Zuevo,
  Moscow region.
• Lower
  Tagil, Sverdlovsk region.
  Russia, Sverdlovsk region, Russia., 622012, г.Nizhny Tagil, Severnoe shosse, 21

The most practical containers for transporting and storing resin are 200-liter steel barrels.

Foaming agent for the production of foam insulation (PO).

PENOISOL typically uses St. Petersburg-produced alkylbenzosulfonic acid (ABSFAC) as a PO during production.Girishi and Voskresensk.

The ABSFC foaming solution should be added to the mortar after being dissolved in warm or hot water for preparation. Simultaneously, 10 cubic meters of production require the amount of ABSFC. The foam needs to be vigorously kneaded with the hands in water for 20 minutes, since the foam becomes a jelly-like mass when it comes into contact with water.

We provide foam insulation software that doesn’t need to be pre-dissolved in warm water. He can be put straight into the mortar. Transport and storage in a polyethylene bag tar. catalyst for curing. (KO)

The foam insulation is cured using the catalyst orthophosphoric acid.

Widely accessible and commercially available. The cost is about 30 rubles per kg. We are also able to supply if needed. Transport and storage in a polypropylene container tare.

To produce one cube, the following foam is needed:

Resin	20kg
Foaming agent	0,5 kg
Catalyst curing	0,6 kg
Water	45 l

According to current prices, 1 cube.m of foam plastic made from components made of KFMT-15 resin costs roughly 135 rubles, while resin VPS-G costs 195 rubles.

Materials for production with your own hands

A brand of insulation called Foam-isol is composed of resin that has been foamed and then solidified (urea resin). Foam insulation production is characterized by its efficiency, affordability, and speed. Completed residential and commercial buildings can be completed with the aid of the resulting insulation if high-quality components were used in the material’s manufacture in the proper ratio.

For the do-it-yourselfer, you will need a foam insulation machine in addition to some other tools.

Self-made foam insulation is easy, quick, cheap, and simple. Technologies that are both safe and reasonably priced can drastically cut down on insulation costs and construction time. One of the characteristics of foamisol is its capacity to fill in gaps by penetrating deeply. It offers superior sound and thermal insulation and is simple to apply.

Making foam insulation with your hands is incredibly simple.

Supplies required to create foam insulation:

• Urea resin (polymer);
• Hardener;
• Foaming agent;
• Water (it is specially prepared).

Usually, foamisol is made using the current machinery. However, if you don’t have it, you can put it together by hand. To produce at home, you will need a generator, a compressor, a power source, a pump for the foam, and a pump for the solution. Using a foam generator, foamisol is best made on the construction site.

Let"s study the design features of the device

As you are aware, the modern construction industry makes extensive use of self-made foam concrete in a variety of categories. These materials’ popularity is understandable given their wide range of advantageous qualities, which essentially have no bearing on their price. Studying the characteristics and parts of the material that should be produced as a result will help you comprehend the design elements of DIY foam generators. Naturally, we are referring to foam concrete in this instance, which is typically created using the following ingredients:

• Foaming agent;
• cement;
• Sand;
• water.

Production process flow diagram for foam concrete: 1 tank (containing the foaming agent solution), 2 service platforms, 3 compressors, 4 foam generators, 5 mixers, 6 pressure hoses, and 7 tiered molds

It is important to note that making foam blocks by hand is a very financially sensible endeavor. These building materials are less expensive than comparable products on the domestic market. This is mainly because manufacturing factory analogs of foam concrete require far higher levels of technology. When discussing the cost of a typical set of components needed to produce building material, it should be noted that the purchase of cement is anticipated to incur the largest outlay of funds. The cost of the necessary quantity of concrete will not be surpassed by the other components in the total amount.

Pros of urea foam and disadvantages

A white, airy, elastic, and porous mass is known as urea foam. All gaps and fissures in the field, ceiling, and wall are filled with foam. Foam insulation turns into a porous insulator after solidification.

Urea foam has the qualities of strength, fire resistance, and durability.

The benefits of foam insulation

1. The material is quite strong and durable. At the same time, they emphasize the cost-effectiveness of foam plastic. Foam insulation serves from 50 to 70 years.
2. The material retains heat perfectly.
3. Suitable for all surfaces.
4. Foam insulation is air permeable. This makes the material breathable and does not accumulate condensation.
5. Fire resistance of foam plastic. When in contact with a flame, the source of ignition is extinguished.
6. Rodents do not spoil the material. Foam insulation is not affected by fungus and mold.
7. Resistant to chemical reagents.
8. Foam plastic is safe for the environment and human health.

Foam insulation, however, is not without drawbacks. Thus, take note of the material’s propensity to shrink. When foam insulation cures, it has an unpleasant smell. It may discuss subpar materials and technological violations in the production process.

The material’s smell should be taken into consideration when purchasing foam insulation. The quality of the material will be low if it smells bad.

Foam insulation has more benefits than drawbacks. Conversely, polystyrene foam, a comparable substance, is unstable to UV light, incompatible with certain materials, and not air permeable. It can also catch fire. Although the two materials are similar, the methods used in their production are not.

Proceed to the production unit

A thorough drawing of the intended machine must be prepared before moving on to the direct assembly of the components. Recall that creating a foam generator for foam concrete requires a design that is both maximally productive and, of course, simple and dependable. The foam that is produced on the unit needs to be sufficiently dense and of a high quality in order for it to be used as building material.

The foam generator’s schematic, put together by a master novice

The foam generator’s design includes shut-off mechanisms that, in the event that the system needs to be shut down, and regulating valves that set the foam’s density. Therefore, the only structural principle used by this home-made device is paired valves, which is well-known in the technical sciences. In order to set the required indicator of the density of the produced foam, valves must be adjusted during the device’s initial operation. The appliance’s owner will only have to modify the shut-off valves in the future.

Section’s foam generator

The machine’s parts that need to be drawn on the drawings are as follows:

• turbulent mixing chamber;
• Nozzle or washer;
• Foam entry and exit points;
• Styrofoam.

Consequently, one of the machine’s most important parts is the turbulent mixing chamber. It’s where the previously made solution is submerged. The mixture is thoroughly mixed inside the chamber before going through a double-truncated nozzle at a specific pressure. The pressurized mortar is considerably compressed when it enters the system and expands when it exits. The speed at which the mixture moves is greatly accelerated in the event of expansion. The concrete mortar enters the foam chamber after leaving the truncated nozzle and turns into a frothy substance.

The foam generator assembly scheme drawing

It is noteworthy that a washer-jackler can be used in place of the aval nozzle if the equipment is only going to be used temporarily and high performance is not absolutely required.

Operation of the foam generator

Prior to constructing a foam generator for foam concrete by hand, one must comprehend the fundamental workings of this apparatus. Air is mixed during the foam supply process, which is done in a dedicated chamber.

The resulting foam mixture is forced to a specific pressure before exiting through the nozzle. And it is imperative to accomplish that the dense mixture was compressed upon entry and expanded upon exit. Additionally, while the equipment is operating, it is imperative to keep an eye on the speed parameters. The mixture thickens into foam inside the foamatron.

In certain designs, a washer-jacket is used in place of the nozzle, however this could drastically lower the foam generator’s efficiency. You can utilize a design that incorporates a jig washer if you require a foam generator for short-term use.

A compressor must be connected to the plan in order for the foam generator to operate steadily and effectively. This will give the system a pressure of six atm.

It is acceptable to use a 200-liter tank as a reservoir; this will guarantee that there is always foam available for the foam generator.

However, using a more potent compressor becomes necessary as production volume rises. Therefore, it will be essential to buy a compressor with specific technical qualities in order to build a foam generator for foam concrete by hand that was effective.

500 liters per minute can be produced when a pump is used in the production process to generate a pressure of two atm.

The production volume can be increased by at least 100 liters if you use a compressor and receiver set to 6 atm of pressure.

Thermal insulation of the facade with cladding boards

The following is how the work is completed:

• The required number of plate and profile elements for the entire facade surface is calculated;
• To the facade of the building, using dowels (wooden plugs) and self-tapping screws, galvanized steel profiles are attached;
• The magnesite boards are installed and fixed on the steel frame;
• Holes are drilled staggered in the constructed cladding;
• With the help of specialized pumping equipment, liquid foam insulation is pumped into the holes. The order of filling voids – from bottom to top;
• Upon completion of insulation work, the holes are sealed;
• At the finishing stage the decorative finishing of the facade is started, which can be done with the use of plaster and painting compositions.

Underneath the siding, thermal insulation

The magnesite boards can be swapped out for another sheet material of finishing if preferred.

Foam insulation requires a lot of labor during the installation process. However, you can and should use it for DIY home insulation due to its low cost and excellent thermal insulation performance.

Basics

There are two ways that foam insulation can be made: on the construction site, in liquid form, or in ready-made molds that fit specific dimensions. Four ingredients are combined to make foam-isol, or urea foam:

• tap water;
• foaming agent;
• special catalyst for curing;
• urea formaldehyde resin .

Items required in the manufacturing process of foam insulation:

• Gas-liquid unit (in which the necessary ingredients will be mixed);
• compressor;
• molds (containers) for foam insulation production.

More apparatus will also be needed (ventilation, lighting, various devices).

Foam insulation production. Classic method

When filling wall voids directly at the construction site, or at the customer’s facility, foam insulation is created using "Classic" technology.

The primary characteristic that sets this method of producing foam insulation apart is the passage of water under pressure through a specific channel known as a foaming agent, into which a unique acid is introduced. The resultant mixture is subjected to a pressurized air stream in the blowing agent, which foams the original mixture to create a fine-porous, closed-cell, and homogenous foam. This foam is then combined with a unique resin, which encases the water bubbles as they form. Since resin can only harden in an acidic environment, when it comes into contact with acid, a scientific process known as resin polymerization occurs within 10 to 15 minutes.

Thus, we have a thermal foam volumetric structure. The next step involves extracting the moisture from the final product, which can amount to nearly 40 liters per cubic meter. Owing to the water-repellent qualities of foam insulation, the total removal of moisture—that is, drying out the foam insulation—occurs in one to two days, contingent upon the local climate, seasonality, humidity levels in the surrounding air, and temperature regime.

How to assemble a working plant

Purchasing a spraying unit for building a house is illogical. If you have one stacked in your arsenal, it’s far less expensive to rent one or assemble one yourself:

• Gas-liquid unit;
• Compressor;
• Transportation platform for the containers.

The compressor and installation are linked in series. After filling the container with mortar and turning on the machine, the insulation layers are applied to the walls, ceilings, floors, and molds, layer by layer and row by row.

If you have never insulated with sprayed materials before, you should seek professional assistance or try your strength on a different surface, like an unnecessary board.

It is crucial that there be no spitting and that the atomization be uniform. If required, modify the solution supply’s power.

Types of equipment for foam insulation with their own hands basic technique

Although insulation production can be set up in any room, it is advisable to do it on-site to reduce transportation expenses.

To assemble the unit, you’ll need:

1. Foam pump.
2. Foam generator.
3. Mortar pump.
4. Electricity.
5. Compressor.

Today’s construction market offers a variety of manufacturers’ insulation production equipment. The features and price of the models vary. The device costs 35,000 rubles on average. It is advised by experts to prioritize installations made in Russia or Ukraine.

Process technology

Completed foam insulation sheetsThis kind of insulation bears a striking resemblance to marshmallow. Because inexpensive and useful composites are used as raw materials, it is very economical to manufacture and not at all difficult.

A semi-liquid foam is produced if the technology is used as directed.

The formed mass straightens out indentations from pressing on it as soon as it dries and becomes quite elastic.

Positives include the material’s excellent heat retention properties and, with proper use, an endless service life.

Using a foam generator, create carbide foam by combining the following ingredients:

• plain water;
• blowing agent;
• Technical catalyst for obtaining a solid sealant;
• urea formaldehyde type resin.

After preparing a specific kind of urea resin, an acid solution and a unique blowing agent are added. A specific amount of the components are added to the pressurized air foam generating unit.

A rich, frothy mass emerges after mixing. It is poured right away into the holes ready for filling before it solidifies.

The consistency of freshly made foam is a lot like that of white jelly. is non-flammable, effectively seals all gaps and openings, and provides good room insulation.

Installing foam insulation inside the wallsThe newly composed material takes time to cure. It sets slightly ten or fifteen minutes after removing it from the generator. It hardens after a few hours, but not to the necessary strength.

It takes a day or three to reach a sufficient strength. It dries out fairly well and acquires all the necessary qualities during this time.

Both the quality and cost of the insulation are very good.

The installation of this kind of insulation proceeds several times more quickly than with other materials. Foam insulation’s potential for use in lightweight construction creates opportunities for competition and future growth.

Requirements for foam generator assemblies and components

The nozzle’s depth must be at least 30 millimeters and must match the size of the entrance hole. Three times the nozzle depth must be the diameter of the outlet opening. Ten millimeters should be the diameter of the central hole.

To make the foam pad by hand, you must adhere to the following guidelines:

• To obtain 200 liters of foam, the foam pad should have a diameter of 40 mm and a length of 800 mm;
• To obtain 500 liters of foam, the foam pad should have a diameter of 80 mm and a length of 800 mm.

There should be a filler in the foam patron; stainless steel nets work well for this because they are consistently shielded from moisture and chemical damage.

To achieve the desired effect, the mesh should be constructed using wire with the minimum cross-section. During the assembly of the foam generator, the remaining assemblies need to be adjusted.

Advantages of the material

This is the most recent advancement in foam insulation, offering superior insulating properties, complete void filling, and user-friendliness.

Because of its high flowability, foamisol can fill any space, insulating against heat and sound, resisting burning, and producing no toxic emissions.

These characteristics allow the material to be used in already-constructed buildings in addition to during construction. When applied, foam insulation doesn’t expand and doesn’t damage the walls.

The material solidifies and hardens after pouring, making it easier to build lightweight, temporary structures that can be relocated later. Examples of these structures include trading kiosks and tiny warehouses.

Advantages of foam insulation

Why experts select this insulator in various configurations:

• Low thermal conductivity coefficient is the main advantage of the material. A layer of 45 mm of ready-made insulation is equivalent in characteristics to a layer of 75 mm foam or 125 mm minwool;
• The elasticity of solidified foam makes the insulation of walls with foam insulation effective – the material fills all the space between the structural layers, without leaving cold bridges;
• High adhesion to any surface;
• Vapor permeability: due to open pores it does not retain moisture on the wall surface;
• On foam insulation does not breed fungi;
• Insulation does not change its characteristics in severe frost or significant heating, when the temperature normalizes, the solidified foam remains elastic;
• Raw material for foam insulation is inexpensive, accordingly, insulation can be carried out saving the family budget.

Insulation foam insulation what it is and what it consists of

Foam is frequently used to insulate homes. Penoizol is a great substitute for all of the current insulators. The primary benefit of using foam is its inexpensive cost.

It is 2.5 times less expensive on average than using polyurethane foam.

The product can be ready at the building site right away. The part is hammered into every crack on the exterior of the house with the use of a hose. To insulate external surfaces, drill holes between the cladding and the primary masonry using this technique.

The following materials are required to produce foam insulation:

• Urea-formaldehyde resin;
• Foaming agent;
• Orthophosphoric acid acts as a catalyst;
• Water.

Air compressors, hoses, and a specialized installation are required in order to produce liquid foam. Foam insulation shares a structure with polyurethane foam. However, the material is less expensive despite having the same qualities.

In production, foam is created by filling specific containers. The material is then cut while adhering to specific measurements. The mixture can be made right away at the construction site, if that is what is desired. The foam insulation will fully solidify in three to five days. However, the polymerization process starts after just ten minutes, and the mixture starts to resemble assembly foam.

Cheaper to order or make with your own hands

Purchasing such equipment is pointless if only one or two objects need to be insulated. Equipment for foam insulation can be made by hand or rented. The average cost of this will be 10,000 rubles.

Self-assembly of the installation

The equipment’s parts are reasonably priced when purchased online. You can accomplish this by going to the websites of the businesses that make it. These businesses offer inexpensive drawing purchases and process technology training.

The least expensive choice is a gadget with:

1. Set of taps.
2. Gas-liquid unit.
3. Hose for supplying the mixture.
4. Plastic drums for mortar with catalyst (300 liters).
5. compressor.

During the process, the solution will be absorbed by the hand-made foam insulation installation and combined with urea resin. Air is used to help foam the components.

When building the installation, it’s crucial to purchase a high-quality pump for pumping the finished mixture. It might be an NSH6 type unit.

A unit that generates double foaming is a useful one for insulation production.

Purchasing a compressor with a specific capacity is also worthwhile. At the outlet, the pump ought to generate roughly 4-5 atmospheres.

Vortex or plunger installations should be prioritized when selecting a unit. The supply of components will be error-free in this instance. Using these pumps has the drawback that no large, solid particles should enter them. The system needs to have more filters added for this reason.

Both the internal components and the pump casing ought to be constructed from high-quality metal. It will be required to purchase a unit from a reputable seller in order to do this. Selecting a pump with a ceramic or stainless steel coating is crucial. It will last a very long time in this instance.

If you follow the guidelines when building a foam insulation apparatus, the mixture will have a high caliber outcome. It will be colored white. The mortar will remain elastic after solidification as well. The video provides more in-depth details about the work being done on the pre-made equipment.

Grating for foam insulation boards

To guarantee proper foam insulation bonding with wall construction, battens made of wood or metal must be constructed. If you go with the wooden option, you will need to apply additional antiseptic to the frame elements.

Observe this: Strict selection is made of the bar cross-section based on the estimated width of the insulating layer.

The installation of the batten structure follows this order:

1. Mark the areas on the facade where the main elements of the purlins are to be fixed to the wall;
2. Drill holes for fasteners in the intended places;
3. Fill the holes with cement or gypsum mortar, and then, using a hammer, hammer wooden plugs into them;
4. Install vertical elements of the purlins and fix them with self-tapping screws (on hammered wooden plugs). Spacing of guide bars – up to 1 m.

When utilizing foam insulation Waterproofing or vapor film laying is not required. It will also prevent the wall from breathing and prevent the insulation from drying out.

The horizontal components are positioned approximately 0.5 meters apart on the vertical bars.

Applying the foam insulation material can now begin. Due to its liquid nature, a limiting grid will be needed as an extra component of the batten structure. To ensure that the foam insulation is properly fixed until it dries completely, it is insulated and fastened to the frame.

The finish is mounted on the previously insulated surface as the final step. For the purpose of internal room thermal insulation, the same technique can be applied. In this instance, gypsum board serves as the finishing material.

We have already discussed using purlin construction to insulate external surfaces with foam insulation. Think about additional structural insulation options.

What is hidden under such a construction concept

Nevertheless, to start a company in this field of endeavor, you must buy And since there will be a lot riding on this solution, it must be approached responsibly.

The fact that foam insulation is the least expensive type of insulation and has many benefits justifies the creation of the material. Foam with a urea-formaldehyde composition is concealed beneath this substance. To put it another way, it’s a foam mixture made of derivatives of formaldehyde and carbide. Water, blowing agent, catalyst, and resin are the primary ingredients used in the creation of foam insulation.

Foam insulation is an essential component in modern construction, offering efficient thermal protection for homes and buildings. Developing a business plan for producing foam insulation involves careful consideration of market demand, production processes, and financial viability. Understanding the needs of customers, such as homeowners and construction companies, is crucial for tailoring products to meet their requirements effectively. Moreover, incorporating sustainable practices in production can enhance the appeal of the business to environmentally conscious consumers. A thorough analysis of production costs, including materials, labor, and equipment, is necessary to ensure competitive pricing while maintaining profitability. Additionally, implementing quality control measures throughout the manufacturing process is vital to deliver reliable insulation products. By addressing these key aspects, a well-crafted business plan can pave the way for a successful venture in the foam insulation industry.

Foam insulation with their own hands home laboratory

It’s not always easy to find a liquid polymer for spraying, so think about how you could make a functional solution on your own. What must be prepared for cooking:

• Urea-formaldehyde resin;
• Foaming agent;
• Technical tap water;
• Orthophosphoric acid.

You can buy ingredients at a building supply store or chemical goods department.

Keep in mind that the parts only last a few months on shelf. It is essential to use only fresh raw materials in order to produce a normal functioning foam.

If not, the insulation will become unstable, the layer will break, and there will be significant shrinkage.

The ratios of the ingredients used to create the solution can vary based on the desired foam properties. Take more resin and acid, respectively, if you need dense foam insulation; take less for loose foam.

You’ll need the following to prepare 1 m3 of foamizol:

• Resin 6…70 liters (more resin – denser foam). The material is heated to 20°C or more, filtering and viscosity control is not necessary;
• Water is heated to 20 and more degrees. Ordinary tap water can be used. Its quantity is determined conditionally until the foam reaches the desired property, the reference point is approximately the same volume as the resin;
• Alkylbenzenesulfonic acid (ABSA) blowing agent in the amount of 0.5…1.0% of the total volume after mixing resin and water;
• Catalyst – orthophosphoric acid is taken in the amount of 0,2…0,5% of the total volume.

To create M15 grade foam insulation, take:

• Resin = 20 kg;
• Water = 24.5 kg;
• Foaming agent = 0.1 kg;
• Acid = 0.4 kg.
• Additives to reduce cracking – resorcinol (50 gr.).

The foam insulation ingredients are combined and then added to the atomizer’s container.

Characteristic features of the apparatus

The cost of the technology used to produce foam insulation is not very high. On the other hand, the equipment that was purchased has excellent productivity, affordability, and simplicity of installation. Furthermore, its size is fairly small. This factor enables the production site’s size to be moderately large. Just finding a storage room will do.

Another feature of foam insulation production technology is its high payback rate. Based on calculations, we can conclude that even if the material is used in a small house, the cost of all the equipment will soon pay for itself.

Advantages and disadvantages of foam insulation

Penoisol is a thin foam made of urea and formaldehyde that is a member of the organic material genus.

It is utilized for ground base insulation as well as for the thermal and acoustic insulation of buildings.

It is not as well-known as its equivalents because it entered the building materials market not too long ago.

Let’s examine its advantages and disadvantages.

Foam insulation benefits include:

• As stated earlier, it is not only heat-insulating, but also noise-absorbing material;
• Penoisol, unlike many insulators, is not eaten by rodents;
• The material is resistant to rot;
• When exposed to high temperatures, it is not inflammable, does not melt and does not smoke;
• It is a breathable thermal insulation material;
• Penoisol has a fluid structure, and solidifies only on the insulated surface when it interacts with air. It allows you to achieve high-quality insulation of complex wall structures, since it fills even the smallest gaps and cracks;
• There is no limitation in terms of service life;
• Foam-isol thermal insulation can be reinforced. This can be achieved by introducing mineral additives in the basic material;
• The price of the material is relatively low.

Drawbacks:

• Gives high shrinkage;
• Difficulty of installation works. Use of foam insulation requires certain knowledge and experience in working with the material, as the application requires strict adherence to technology.
• When insulating frame structures, it is difficult to predict how such insulation will behave. When solidifying foam insulation gives shrinkage, as a result huge voids can occur, which will already be problematic to fill.
• The material is fragile, so it is necessary to cover it with other materials having greater mechanical strength.

Crucial! According to some sources, foam insulation is a hazardous material that releases noxious gases. Some people, however, believe that this process only takes place when the insulator is solidifying.

Independent installation of the installation

The foam insulator sketch. (Toggle to make larger)

You can purchase installation drawings and discover production technology on the websites of companies that make equipment for foam insulation production.

You can assemble this machine yourself after purchasing such a package of documents, especially because spare parts are constantly available.

One low-cost alternative will be a hand-assembled structure made up of:

• gas-liquid installation;
• tap set;
• supply hose;
• compressor, for the production of compressed air;
• plastic drums up to 300 liters.

The idea behind creating insulation is to foam solutions using a catalyst and combine them with urea resin. The components are transported to the unit with the use of a pump, where they are foamed by compressed air.

Foam insulation system schematic diagram. (Toggle to make larger)

The pump is one of the key parts of the system in the gas-liquid installation, so it is best to purchase a high-quality pump.

Pumps like the NSH 6 (gear pump) and NSH 10 are not recommended because they may not work properly in terms of dosage when feeding resin, one of the components.

The electric motor on these pumps is likewise having issues. When supplying the completed product to fill voids, the specified power might not be adequate.

Consider: Dosing errors and errors in the instability of motor speed from voltage and load must be considered when choosing pumps for the installation.

Using vortex or plunger pumps is more beneficial. Here, dosage errors are no longer possible, but if solid particles enter the system, the entire operation may be interfered with, resulting in anything from machine breakdown to dosage failure.

Remember that the material of the internal parts is crucial to consider when selecting a plunger or vortex pump. It should ideally be made of ceramic, stainless steel, nickel plating, or plastic.

Buying a high-quality plunger pump is also desirable for the foam supply pump. A low pressure, high foaming ratio generator creates foam. Foam with a lovely fine cell structure is the result.

Double foaming is the most efficient technique available today. At the output, foam-isol is visible as a dry mass that prevents it from flowing out of the filled cavity.

The equipment’s compressor needs to be installed with a specific capacity. Make sure to monitor the resin consumption; for a high-quality product, it should not exceed 25 kg.

Completed foam insulation

To distribute the insulation throughout the fill volume in the foam insulation plant, the ideal ratio of each component must be established.

The finished item should be white in color and return to its original shape when pressed.

Foam insulation is a useful insulator for in-house production because of its high insulating qualities and low production costs.

Once the equipment is put together in accordance with the blueprints, you can launch a small business and begin making money. Foam insulation’s field of application is growing, so its production can be considered promising.

Watch the video to see how the steps of working on the foam insulation equipment with their own hands are demonstrated in detail:

• 1 Advantages of the material
• 2 Composition and application
• 3 Self-installation of the installation

Forms of material

There are various ways that foam insulation is brought to the construction site:

1. Liquid. This is the most common form. Installation requires special spraying equipment for foam insulation, which delivers the prepared solution under pressure. The setting of the applied foam begins in 10-15 minutes, primary curing occurs in 3 hours, the material finally hardens in 2-3 days. Finished insulation is an elastic substance of medium rigidity, capable of restoring its shape after the impact of mechanical load.
2. Sheet. This is the second most popular type of foam insulation. The same solution of resin and acid is used to make sheets (slabs). It is sprayed into molds, where it solidifies to a working state, after which it is attached to walls and ceilings as any plate insulator.
3. Granular. This is a foam insulation crumb obtained as a result of crushing sheet materials, often defective ones. The trick of crushing is to increase the volume of insulation up to 3 times, while its technical properties are not reduced. Granules (crumb) have found application in insulation of basement and attic, as well as interfloor ceilings.

STANDARD installation

The initial dosage scheme.

The issue with resin dosageDuring operation, adjust the pump’s capacity directly.

Filtration of resin is not required.Working fluids can be sucked through the top of drums thanks to this system.

• No need for special barrels.
• No taps that constantly break off.
• The working components can be drawn from any containers.
• It is not necessary to transfer resin manually from heavy drums to the staff.
  It is enough to dip the suction pipe into another barrel. This dramatically increases labor productivity.
• There are 2 persons on this machine, who are free to operate it 60 m³ per shift.

Large radius of action.40m (30m mixing + 10m feeding hoses)initial foam production systemSupply system consisting of just two hoses for the operational components

Unique style and practical housing Installation "Standard" is its name.

Equipment: Pumping unit; two pieces of 5 m suction hoses for components; a set of 30 m supply hoses; a 10-meter mixing hose

Gas-liquid unit GZhU -1 for the production of foam insulator.

A cost of 24,900 rubles.

Our plant allows us to produce heat and sound insulating material – urea foam (trade marks penoizol, unipor, mipora, etc.).д.). For 17 years of GZHU production more than 2000 foam insulation plants have been sold. Our experience has made the foam insulation plant easy to operate, light in weight and easy to repair. Installation for the production of foam insulation is assembled from parts that, if necessary, can be bought in any plumbing store. Simplification of the installation has allowed to reduce the cost of the installation of HLU significantly. Our installation for the production of foam insulation is cheaper than some analogs in 2 – 5 times. The small size of the GZhU unit and the simple technology of foam insulation production make it possible to set up foam insulation production in a short period of time (1-2 days) both in stationary conditions and directly on the construction site. To work on the plant for the production of foam insulation is enough for one person. The time to bring the plant into operation is 20-30 minutes. The unit allows to produce foam insulation in sheets, as well as to make foam insulation casting directly at the object.

Pouring foam insulation can be made in the voids of building envelopes, designed to fill with insulation material (well masonry), filling the thermal insulation layer of attic floors, insulation of floors, etc.д. The mixing system we have developed avoids clogging of the foam generator. That is, our DST is almost impossible to "put on a goat". A distinctive feature of our foam insulation plant is the ease of operation: the DST is controlled by only one crane. The "foam" tap regulates the density of the foam insulation. More foam – less density, less foam – higher density. The second tap (resin) is always open. Any sequence of switching pumps on and off and air supply. The possibility of clogging the foam generator with resin is almost completely excluded. This was the result of 14 years of experience in the production of DST units.

Included in the supply are the GZhU-1 unit, supply hose, three pieces of cocks for connecting tanks, passport, and technical regulations. The foam insulation plant is delivered in a cardboard or polyethylene box.

Technical details:

Capacity	5 – 6 m3 per hour
Air consumption	400 – 500 liters per minute
Air pressure	2-2.5 atm
Power consumption	0.97 kWh
Supply voltage	220 В
Operating personnel	1 person
Supply of resin and solution	from containers (not included)
Feed hose length	8м
Height (depth) of foam insulation delivery	8м
Net weight	35 kg
Dimensions (DxWxH)	400x400x500mm

One-year guarantee for GZhU installation.

View the remaining videos to learn how our equipment works.

Is supervision of installation necessary? To view the terms and conditions, click.

A cost of 24,900 rubles.

Information request regarding this equipment

It is also advised that you read the following articles:

Non-detachable formwork – profitable buildingWhy is house insulation necessary?Equipment for producing foam insulationFormwork made of foam and rats

Where to set up a foam insulation plant

The entrepreneur must set up a workspace ahead of time for the product release because the drying process’s components release hazardous materials into the air.

You can arrange warehouses for the storage of raw materials and completed goods and place all of the equipment in a shop that is no larger than 100 square meters. Depending on the area, a shop of this size can be rented for 20000-70000 rubles per month.

The following conditions must be met by the business owner in order to prepare the found premises for the start of production:

• Presence of electricity, water, heating, sewerage in the workshop.
• The presence of a properly functioning ventilation system.

You won’t need to hunt for production spaces if you launch a business producing heat insulators on building sites. All that’s required of you is a tiny space to store inventory and equipment. A garage works well too.

Step	Description
Market Research	Study demand for foam insulation in target area.
Competitor Analysis	Identify competitors and analyze their offerings.
Business Model	Determine pricing, distribution channels, and revenue streams.
Regulatory Compliance	Understand local regulations for foam insulation production and sales.
Supply Chain	Source raw materials and establish supplier relationships.
Production Setup	Acquire equipment and set up manufacturing facilities.
Marketing Strategy	Develop a plan to reach target customers and promote products.
Sales Plan	Outline strategies for generating sales and expanding customer base.
Financial Projections	Forecast expenses, revenues, and profitability over time.

Establishing a foam insulation company can be financially rewarding, particularly in light of the growing need in the building sector for energy-efficient solutions. In addition to helping reduce energy use, you can lower heating and cooling expenses for businesses and homes by offering efficient insulation solutions.

Extensive market research is one of the most important components of a successful foam insulation business plan. Developing a strong business plan requires knowing the market for insulation services in your area, spotting possible rivals, and examining pricing tactics. Gaining knowledge about consumer demands and industry trends will help you customize your offerings to fit particular needs and set your company apart from competitors.

To provide great service and guarantee client satisfaction, you must invest in top-notch tools and employee training. Equipped with the right tools, you can install insulation more effectively and efficiently while also projecting professionalism and dependability to your clients. Furthermore, skilled professionals are able to handle client concerns, provide professional advice, and carry out insulation projects precisely and accurately.

Running a successful foam insulation business also requires you to forge strong bonds with manufacturers and suppliers. Forming alliances with reliable suppliers guarantees that you will have access to high-quality materials at reasonable costs, enabling you to keep your business profitable while providing value to your clients. Additionally, working with manufacturers can present chances for education, new product development, and keeping abreast of market advancements.

To sum up, creating a thorough business plan for foam insulation entails analyzing market conditions, making training and equipment investments, and cultivating relationships with manufacturers and suppliers. You can position your company for success in the cutthroat insulation market while also having a positive impact on sustainability and energy efficiency by concentrating on these important areas.