The Manufacturing Process of Blown Insulation
Blown insulation is a great option for improving the comfort and efficiency of your home. It delivers seamless coverage with strong thermal R-values and is perfect for retrofitting existing walls, as it can be installed without removing linings. It also offers excellent acoustic properties, reducing noise while keeping warmth in.
Each bag of blown insulation contains the equivalent of over 45 recycled glass bottles. Let’s take a closer look at how manufacturers transform these materials into high-quality insulation.
The Manufacturing Process, From Glass Bottle to Insulation
1. Gathering and Preparing Raw Materials
The process begins at the batch plant, where workers deliver and store raw materials such as sand, soda ash, borax, and dolomite. However, they use up to 80% recycled glass, also known as cullet. This comes in two forms:
- Plate glass – sourced from windows and car windscreens
- Container glass – from bottles and jars
Workers offload the raw materials into storage silos, where they hold them until needed. The batch plant automatically measures and mixes the correct quantities of each ingredient before feeding them into the furnace.
2. Melting the Glass
The furnace operates at an intense 1,400°C, using a combination of gas, oxygen, and electric boost to melt the raw materials into a bath of molten glass. Unmelted batch materials float on the surface, while powerful gas-oxygen burner flames provide about 70% of the heat.
After melting, the glass travels through electrically heated canals, which maintain the right temperature and viscosity for fibre production.
3. Creating the Fibres
To create the fibres used in blown insulation, the molten glass is rapidly spun through a hot spinner. Centrifugal force forces the molten glass through thousands of tiny holes, creating fine glass fibres. As the fibres emerge, hot air blows them downward, stretching them further. Compressed air then determines the fibre length, while cooling water prepares them for the next stage.
4. Applying the Binder and Silicone Emulsion
Unlike traditional insulation rolls or batts, blown insulation does not require a binder. Instead, a silicone emulsion is applied to help the insulation maintain its shape and effectiveness once installed.
The system evenly distributes the fibres across a conveyor to maintain consistency in density. Quality control teams monitor glass temperature and use CCTV surveillance to ensure the highest standards throughout production.
5. Environmental Considerations
The manufacturing process incorporates stringent environmental controls. Electrostatic precipitators remove pollutants from exhaust gases, and emissions monitoring instruments ensure compliance with environmental standards. The stacks emit very little, mostly steam, which reflects the eco-friendly nature of the process.
Installing Blown Insulation in Your Home with the Healthy Home Team
Once manufacturers produce the insulation, they package it into large bags and transport it to installation sites. The installation process is quick and efficient, making it ideal for both new builds and retrofits. Here’s how it works:
Assessment and Preparation – Your local advisor will assess your home to determine the best insulation solution. If installing into existing walls, small access holes are drilled for installation.
Blowing the Insulation – Specialised blowing machines break up the insulation material and blow it into wall cavities, ceilings, or underfloor areas. The material spreads evenly, filling every gap and eliminating thermal bridges.
Sealing and Clean-up – Once the insulation is in place, any access holes are sealed, leaving no visible signs of installation.
Why Choose Blown Insulation?
Blown insulation provides seamless coverage, eliminating gaps for superior thermal performance. Its fast and non-invasive installation makes it an ideal solution for retrofitting older homes without major disruptions. Designed to be moisture-resistant, it helps prevent mould and damp issues, contributing to a healthier living environment. Made from up to 80% recycled glass, it is a sustainable choice that supports eco-friendly building practices.
Contact the Healthy Home Team
If you’re looking to improve your home’s insulation, we are here to help. Whether you have a question on your homes insulation or want a free quote, our team is ready to assist. Get in touch today and make your home more comfortable and energy-efficient with high-quality blown insulation.