“INSUTECH” upgrades XPS Line to cut energy use

INSUTECH, founded in 1987 in the 10th of Ramadan city, is a leading international company specializing in the manufacturing of comprehensive packaging and insulation solutions. Their diverse product portfolio includes Expanded Polystyrene Foam (EPS), Modified Bituminous Membranes (MBM), and more.

Operating in the insulation technology industry, INSUTECH provides innovative solutions for a wide range of sectors. Their focus areas encompass XPS Foam, Bituminous Emulsions, Crack & Joint Sealants, and other cutting-edge offerings. Notably, their XPS products stand out for their strength, lightweight design, and water resistance.

INSUTECH, a leading manufacturer of insulation and packaging solutions based in 10th of Ramadan City, upgraded its XPS Foam Board Extrusion Production Line with support from GEFF Egypt to improve energy efficiency, increase output, and eliminate harmful refrigerants.

Founded in 1987, INSUTECH serves multiple industries with a broad product range including Expanded Polystyrene Foam (EPS), Modified Bituminous Membranes (MBM), Bituminous Emulsions, and Joint Sealants. Their XPS foam stands out for its durability, light weight, and water resistance.

To stay ahead of regulatory changes and rising demand, INSUTECH invested in replacing its outdated XPS production line—previously reliant on Freon R22, which is scheduled for global phase-out by 2030. The new system uses environmentally friendly blowing agents like CO₂, Ethanol, LPG, and DMA, reducing the company’s climate impact.

With financing from GEFF Egypt, INSUTECH achieved:

• Primary Energy savings of 5,486 MWh per year

• GHG emissions reduction of 956 tCO2eq

• Improved energy efficiency, reducing electricity consumption from 25 to 16 kWh per m³

• Annual output capacity of 180,000 m³, supporting business growth

• Cost savings and operational optimization

The project also created 40 temporary and 10 permanent jobs, reinforcing INSUTECH’s commitment to local employment and responsible business practices.

The GEFF team evaluated the technical and financial feasibility of the project and provided advice on the best available technologies that will enable the company to reduce energy consumption and increase profitability.

The Green Economy Financing Facility (GEFF), was developed by the European Bank for Reconstruction and Development (EBRD) and is financially supported by the EU, EIB and AFD.