Advanced insulation solutions for engineers

Based on a structured analysis of your process. A material choice made without knowledge of the application gives no reliable prediction of performance in your installation. That is why we first map out twelve parameters: maximum pressure load in N/mm², temperature profile (heating only, or cooling as well), cycle frequency, chemical influences such as acids, release agents and solvents, desired temperature on the cold side, fastening method and mounting conditions. Standard advice does not exist in our market. Two seemingly comparable machines can call for completely different material solutions.

The service life ranges from a few years to several decades, depending on six main factors: maximum temperature, cycle frequency, cleaning regime, chemical environment, mechanical load and mounting quality. In a clean, stable environment with a constant load, a panel can last for decades. In an environment with aggressive cleaning, fluctuating temperatures and mechanical wear from penetrating moisture, the service life is shorter. Mounting quality in particular is underestimated. A professionally mounted panel lasts considerably longer.

Yes. For R&D projects and initial testing we supply series from just a few units, with the option to scale up once the solution has proven itself. Where necessary we carry out additional machining, such as fitting metal inserts, or we press different materials together to create a plate that can absorb higher mechanical or thermal loads. We also maintain tolerances on concentricity and squareness. For your first prototype we are glad to provide a no-obligation quote based on your digital drawing, STEP, DWG or DXF file.

A thermal break is a structural insulating element that interrupts heat conduction while continuing to carry the mechanical load. In presses, moulds and steel structures, a thermal break prevents heat from escaping through metal contact surfaces. NOVIUM supplies pressure-resistant insulation panels that fulfil this function, designed around the pressure and temperature range of your specific process.

NOVIUM is active in more than twenty markets, and each has its own requirements for thermal insulation. For rubber processing (vulcanising presses, rubber moulds) we generally work with 300 N/mm² materials. For mould and die building (injection moulds, press moulds, casting moulds, blow moulds), the challenge lies in combining precision, pressure resistance and thermal separation. Placement between the clamping surface and the mould calls for different material properties than placement around hot channels or at the separation between heated and cooled sections (cold runner). For applications where parallelism and thickness tolerance are critical, we supply materials in a Premium Finish grade with tolerances of up to 0.02 mm on both parameters. Woodworking machinery has its own requirements again (coated due to oil exposure). For semiconductor and high-tech machine building, we select materials with high precision and dimensional stability. The packaging and metalworking industries each have their own criteria as well.

For high pressure loads, finely woven composite materials are generally the go-to option. These materials are developed for processes where pressure loads exceed the range of coarsely woven or loose-weave systems, for example in heavy presses or applications with dynamic cyclic loading. The choice between XGD 80 and other variants depends on the interplay between pressure, temperature and cycle frequency.

Exterior insulation of machines, presses or installations requires different material properties than insulation within a process component. Pressure load plays no role here, but insulation value and personnel safety (no risk of contact with hot surfaces) are the key concerns. We select materials that minimise heat radiation and bring the outer surface temperature down to safe levels. Flexible solutions such as BRA-FLEX Protect are suitable for pipes, hoses and irregular surfaces. Rigid panels (S4000A - XGD15) are used where the geometry calls for it.

For applications where temperatures or breakdown voltages exceed the range of standard composite insulation, we select specific high-grade materials. For electrical insulation up to 20 kV we often work with mica-based materials, which combine exceptionally high breakdown resistance with good heat resistance. For other combinations of requirements we work with high-grade fibreglass composites. The specific choice depends on voltage level, maximum temperature and geometric requirements such as concentricity and tolerances.

Yes. As of 1 April 2026, our FP coating has been converted to a PFAS-free, water-based formulation. This change aligns with tightening European regulations around PFAS (the so-called "forever chemicals") and with sustainability requirements in projects such as LEED and BREEAM. The new coating has been extensively tested on all common insulation materials, including S4000, BRA-GLA 3, BRA-GLA SI, KV3eco and XGD 80. The tests covered chemical resistance, adhesion via a cross-cut test, friction and wear, steam resistance, and a thermal endurance test up to 280°C. Conclusion: adhesion and thermal stability are equivalent to the previous coating. The coefficient of friction is marginally higher (around 0.20), which falls within the functional bandwidth for virtually all applications.

Resistance depends on six factors in your cleaning regime: the type of agent (alkaline, acidic, solvent-based, chlorine-containing), the concentration, the temperature, the contact time, the frequency, and the mechanical load (brushes, high pressure, steam, CIP cleaning, i.e. Cleaning-in-Place). Light cleaning such as 50 to 100 ppm active chlorine is acceptable for many insulation materials. Intensive CIP cleaning with high concentrations and prolonged exposure can significantly shorten the lifespan of epoxy resin matrices, adhesive bonds and edge seals. For applications where aggressive cleaning is unavoidable, such as food, biomaterials and pharma, we select materials and finishes developed to withstand chlorine, alkaline cleaning agents and CIP processes.

More than you might think. In many production installations (continuous presses, short-cycle presses, extruders, blown film lines, multi-daylight presses, semiconductor equipment) insulation tends to focus on the main components. Pipes, flexible hoses, valves and small surfaces often remain uninsulated, while substantial heat loss occurs there. An uninsulated pipe can reach a surface temperature of 230°C. With a flexible insulation material such as BRA-FLEX Protect (16 mm thickness), that drops to around 65°C in comparable situations. That represents an energy saving of up to 70 percent, plus a direct benefit for workplace safety. The material can be used from -50°C to +280°C, is flexible to install around bends, reusable and water-resistant.

For our materials we provide the technical data sheet and Safety Data Sheet (SDS) as standard. The manufacturer Brandenburger is ISO 9001:2015 certified, with a valid quality management system for the development, production and sale of thermal insulation materials, valid until 13 July 2027. An EPD (Environmental Product Declaration) or CE certification for the material as a standalone product is not currently available. For most specialist composite materials, this is not unusual, incidentally.

Yes, on material and manufacturing quality. Not on the service life in your application. That distinction is a matter of principle for us. We guarantee that the material meets the specified properties as described in the technical data sheet. The eventual performance in your installation depends on factors outside our control: design, load, fastening, mounting method, cleaning regime and specific application conditions. A product warranty detached from that context would be misleading.

For applications where the load is difficult to estimate in advance, we often get involved in the development process. We supply test samples for trial and error, make test materials available, contribute to validation, and in some cases offer development pricing to make experimentation feasible. This fits with how we work: not just supplying material, but developing solutions guided by practice.

This happens more often than you might think, especially during maintenance, machine overhauls, or when a drawing from the archive goes back into production. Many insulation materials used decades ago have since been discontinued, replaced by improved variants, or phased out due to regulation (think of asbestos-containing materials). NOVIUM maintains an extensive internal database of historical material names, technical descriptions and data drawn from more than forty years of practical experience. As a result, we can propose a modern alternative in nearly all cases, supported by a clear explanation of why this material matches or exceeds the original properties.