September 3,2025, Unilin has raised the bar for sustainability with the opening of the first full-scale recycling facility for PIR (polyisocyanurate) insulation boards in the world in Desselgem, Belgium. This state-of-the-art plant represents a major accomplishment in Unilin’s goal to reduce environmental impact and improve the circularity of insulation products. The €8 million investment in the modern recycling facility enables Unilin to chemically recycle post-industrial PIR insulation boards and internal manufacturing waste into new PIR insulation products. Unilin’s new facility marks a significant milestone in the company’s continuous efforts to lower its carbon footprint and support sustainable construction practices, as it is the first manufacturer in the insulation sector to accomplish this.
PIR insulation boards, which are primarily used in walls, floors, and roofs, are known for their high thermal performance and long lifespan. These boards are made by chemically reacting polyol and MDI (methylene diphenyl diisocyanate), resulting in an insulating material that surpasses traditional materials such as mineral wool, XPS (extruded polystyrene), and EPS (expanded polystyrene) in terms of thermal efficiency.
PIR insulation’s benefits include its higher insulation value per thickness, making it an ideal solution for energy-efficient construction. Its lightweight structure is easy to handle and install, and the boards retain their insulation properties for decades, with little degradation over time. In fact, even after 50 years of use, PIR insulation’s thermal performance remains largely unchanged, further cementing its status as a long-lasting, reliable material for the construction industry.
Unilin’s recycling process
One of the biggest challenges facing PIR insulation products has been circularity. While PIR boards are recyclable, previous methods only allowed for mechanical recycling, which had its limitations. Unilin’s breakthrough came with the development of a chemical recycling process capable of converting waste PIR boards back into raw materials for producing new PIR boards. This self-developed recycling process is a game-changer. It involves a three-step procedure: shredding, filtering, and chemical recycling.
In the first step, the PIR boards are shredded into small pieces.
The next stage uses a specially developed internal procedure to separate the PIR material from the paper or aluminum facing on the panels. The purified PIR is then fed into a glycolysis reactor, which breaks down the material into polyol and other components. The recycled polyol is then reintroduced into the production process, where it is combined with MDI to create new PIR insulation boards. Through this process, Unilin can now self-supply up to 50% of its polyol requirements, marking a major step in reducing reliance on virgin raw materials. As a result, the company is enhancing the sustainability of its products while reducing waste in the construction sector.
The new recycling plant in Desselgem is just the beginning for Unilin. The company plans to gradually ramp up the capacity of the plant, initially focusing on recycling internal board waste before expanding to include post-industrial waste from construction sites. In 2024, Unilin plans to extend its operations with the addition of a recycling plant in the UK, with studies already underway for this expansion.
Beyond scaling up production capacity, Unilin is also exploring further innovations in recycling technologies. The company is researching techniques to not only recycle polyols but also the MDI components, which would bring the recycling process even closer to full circularity.
Unilin has also launched the Unilin Recover program, a take-back initiative designed to collect PIR waste from construction sites and return it to the company’s recycling facilities. By collaborating with the construction industry, this program ensures a steady supply of post-industrial PIR waste to feed into the recycling process. The Recover program is an essential part of the company’s strategy to close the loop on PIR insulation and promote sustainable building practices across Europe.
Unilin’s insulation division
Unilin has firmly established itself as one of Europe’s largest manufacturers of polyurethane (PU) insulation. The company’s product range includes a variety of insulation solutions for residential, commercial, and industrial applications, with well-known brands such as Usystem, Utherm, Usafe, and Rezillo. Unilin operates eight production sites across Western Europe, including in Belgium, the Netherlands, France, the UK, and Ireland, and is currently expanding with a new facility in Poland.
In addition to its groundbreaking work in PIR insulation recycling, Unilin’s commitment to sustainability extends across all areas of its operations. The company is constantly innovating to improve the environmental performance of its products, reduce its carbon footprint, and promote circularity within the construction industry. Unilin’s investment in the Desselgem recycling plant is a testament to the company’s leadership in advancing sustainable building materials. As demand for energy-efficient insulation products continues to grow, Unilin is poised to play a crucial role in shaping the future of the construction industry.
Unilin is cutting waste and carbon emissions by being the first company to recycle PIR insulation boards chemically. They are also laying the groundwork for a more sustainable and circular economy in the building industry. The closed-loop PIR insulation system that the company had envisioned is now a reality, and more innovation and growth are planned.
Source: woodandpanel.us
