Thermal Insulator Production Plant
End-to-end scaling with Orkli S. Coop — Patent WO 2025/132956 A1
At InVerTec, we collaborate closely with our industrial partners to execute end-to-end scaling projects, guiding innovations from initial material formulation all the way through to full-scale production. A prime example of this holistic approach is our work with Orkli S. Coop to develop and industrialize a novel thermal insulator (Patent WO 2025/132956 A1).
Material Formulation
Working in tandem with Orkli and the University of Bayreuth, we engineered a glass fiber-based composite insulator. Utilizing a structured Design of Experiments (DoE), we systematically tailored the material to meet the client's target specifications. This involved comprehensive laboratory testing to verify the composite's thermal isolation capabilities, physical stress limits, and resistance to chemical degradation.
System Design
Transitioning from the laboratory, we collaborated with specialized partners to design the manufacturing hardware. At the core of the process, we engineered a unique compaction unit featuring synchronized vacuum and pressure dynamics. Beyond this central technology, we placed a heavy emphasis on the complete process ecosystem, designing integrated peripheral networks, specialized upstream feeding mechanisms, and efficient downstream recovery units.
Pilot Plant Construction and Validation
As a core part of our scaling process, we built and operated a pilot-scale production chain alongside our partners. This critical step allowed us to stress-test the system, identify operational bottlenecks, and resolve early process limitations. By fine-tuning the process-related parameters in a dynamic environment, we maximized operational efficiency while strictly preserving the required structural properties of the glass fiber composite.
Industrial Implementation
The project culminated in the deployment of a full-scale mass production facility in Spain. We provided comprehensive engineering support across the entire plant architecture—managing raw feedstock preparation, the core product transformation, and the safe handling of waste streams. Our team delivered the finalized mass balances, detailed process flowsheets, and critical instrumentation layouts. In addition, we actively advised on supplier contacts and equipment purchasing. Finally, we collaborated directly on the software integration and electronic signal processing to ensure the highly automated, high-volume manufacturing of precision-dimensioned parts.
