Industrial Energy Minute | The difference between thermal barrier and ceramic coatings.
What's the BIG Difference?
The difference between advanced thermal barrier coatings and ceramic coatings can mean a lot for your corporate sustainability goals. Exceptional results!
Sustainable Leaders in over 60 countries around the world are choosing INI's advanced thermal barrier coatings over other methods to insulate heat process equipment and building envelopes, and there's a reason: Ceramic coatings, invented in the 20th century, were a new idea back then and insulating with a coating became popular because it was simple and cost effective to apply.
Fast forward to today: Just like computers and smart phones, insulating coating technologies have progressed leaps and bounds since the mid-1900’s. Our patented technology is quite innovative and different than the coatings of the last century. Our advanced coating line does more than just provide superior insulation, there are many other benefits enabled by our R & D and the scientific advancements in the 21st century. This is why once plant and facility managers discover us, and learn about the advancements, although they can choose any product, they choose us! And, this includes the vast number of plant and facility managers that choose our technology not over just ceramic coatings, but also instead of the even older fiberglass or mineral wool technologies that actually create problems, such as CUI.
Are INI Coatings and Ceramic Coatings Different?
Yes, they really are. Completely.
It is completely understandable that all “insulating paint” technologies would be considered to provide similar performance. But just like your flip phone from 1995 may let you talk to someone like your Galaxy smart phone of 2016 – it’s easy to see that they are completely different, and one is way more advanced than the other.
With coatings, much of the advancement is in hidden in the chemistry and physics… the way the molecules interact with each other, the substrate and moisture. Let’s take a look at the key advancements of INI's thermal barrier coatings over the older ceramic coating technology.
1. Appearance
Ceramic coatings tend to be white or tinted a light color. There is a big reason that they tend to be white (see item #3).
INI coatings are clear, with the exception of EPX4 and the large particle size in this supercharged formula is the main reason for that. Clear gives you the ability to see the surface through the coating, which is a huge help both in pipe and equipment applications (visual inspections for corrosion through the coating) and for buildings (insulate without losing the color or beauty of the architecture).
2. Thickness
INI thermal barrier coatings are applied between 4 mils (clear coatings) to 10 mils (EPX) and spray easily through either a standard paint sprayer (clear coatings) or a texture sprayer (EPX). No clogging and no frustration.
Ceramic coatings are typically much thicker and are usually applied at about 20 mils per coat. Making it more difficult to go through a standard sprayer. This also impacts the coverage rate per gallon for a standard application, and thus the application costs.
3. Reflection versus Thermal Insulation
Ceramic coatings primarily use ceramic microspheres, also known as microscopic glass beads, to trap air as a way to try to insulate, but it’s well known that a large portion of their “insulating” ability is from the sun reflecting off the white surface.
They are used often as white roof coatings in warm climates because of that fact a white reflective coating will help keep a building cooler, but bring on the cold temperatures of winter and a white reflective coating can actually raise heating bills, negating the benefit in the hotter months. This is called the “heat penalty”.
In industrial settings on pipes and tanks, the substantial thickness needed to accomplish basic performance levels makes application and material costs substantially increase the time it takes for the payback in real dollar energy savings… which, at the end of the day, is what the goals of thermal insulation are really about.
21st century thermal barrier coatings by INI work like a true insulator. Just like the thick insulation in your attic or on your pipes – they reduce heat transfer directly – thus insulating equally as well in all seasons and indoors or outdoors, and whether the heat is outside or inside a pipe or tank. Our coatings work in all seasons, all day, every day.
4. Multiple Benefits
20th century ceramic coatings tend to be single purpose, doing one thing and not much else. What our customers tell us is that they are very happy to experience the multiple solutions that our thermal barrier coatings give them. We do more than they ever imagined!
Besides insulating for energy savings and surface temperature reduction, they…
Prevent corrosion and corrosion under insulation (CUI)
Are resistant to mold and mildew growth
Provide protection from harmful UV rays
Have exceptional splash resistance to acids, bases and fuels (EPX)
Can be used up to 400F/204C
Are extremely moisture resistant, while still being breathable
5. Consistency - Patented vs Non-Patented
We pride ourselves on our stringent quality control. Because we developed our patented technology with leading scientists, manufacture it in a ISO 9001 certified facility, and only sell it under our corporate brand, you always know what you’re getting when you purchase our coatings.
The same may not be true with the plethora of ceramic coatings on the market. They are sold under a wide variety of brand names by different companies, and as a result can have varying product performances.
Take a Closer Look at Thermal Barrier Coatings
Who has already discovered 21st century thermal barrier coatings? Many companies around the globe, from large international airports using them for building energy efficiency to globally recognized brands in manufacturing and the food and beverage industry. Even centuries old manufacturing companies choose INI coatings to solve age-old issues with failing insulation and increasing energy costs, implementing multi-country sustainability projects to save energy and lower their carbon footprints.
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Email: contact@industrial-nanotech.com
Phone: 800-767-3998 or +1 239-254-0346
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Industrial Nanotech, Inc.
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Naples, FL 34109 USA
