Save 20-40% Energy on Barrel Heating
Barrel insulation jackets are one of the fastest-returning investments in plastics processing and industry as a whole. A well-fitted insulation jacket on the heater bands of an injection moulding machine or extruder cylinder reduces heat loss by 20% to 40%.
At Technic Solution, we design and sew thermal insulation jackets individually for each machine — from the plastifying units of injection moulding machines and extruders, through boilers and industrial valves, to machine bodies and pre-heated moulds. Every project starts with real on-machine measurements and ends with a jacket fitted so precisely that it eliminates thermal bridges, which are the main source of energy loss.
Investment in barrel insulation jackets pays back quickly, and the jackets run for years without losing performance. It is one of the cheapest and fastest-acting methods of reducing electricity bills in a production hall.
What Are Barrel Insulation Jackets?
Barrel insulation jackets (also known as heater band insulation blankets or thermal insulation jackets) are flexible insulating covers, sewn to measure and fitted onto the heating elements of industrial machinery. The standard thickness is 25 mm, but depending on the available space and temperature requirements we manufacture thinner jackets (e.g. 15-20 mm) or thicker ones (up to 40-50 mm), as well as aerogel variants — using the material with the lowest thermal conductivity commercially available.
Our jackets consist of three layers: an inner contact layer resistant to the heater surface temperature (up to 600°C), a middle insulating layer made of ceramic fibre or aerogel, and an outer protective layer made of coated fabric that resists mechanical damage, oils and chemical agents typical of a production hall environment.
Benefits of Thermal Insulation Jackets
- Energy consumption reduction of 20-40% on the heating system of an injection moulding machine, extruder or other industrial equipment.
- Longer heater band lifespan — heater bands cycle less frequently and work under milder thermal conditions.
- Process temperature stability — smaller fluctuations inside the barrel translate into more repeatable injection and lower defect rates.
- Operator safety — the jacket surface temperature is significantly lower than that of a bare heater, eliminating the risk of burns during machine service.
- Lower production hall temperature — less heat radiating into the environment means lower ventilation and air-conditioning costs and better working comfort.
- Carbon footprint reduction — lower energy consumption means lower CO₂ emissions, supporting your plant’s sustainability goals.
Applications – Where Our Insulation Jackets Perform Best
While the majority of our production goes into insulation jackets for injection moulding machines and extruders in the plastics processing industry, Technic Solution insulation jackets work wherever heat escapes from heated machine components and industrial installations.
Injection Moulding Machines and Extruders – Plastifying Unit
Our main application is barrel insulation on injection moulding machines and extruders. Insulation covers the entire plastifying unit — from the feed zone, through the heating zones of the barrel, to the nozzle. Each heater band receives its own dedicated jacket, which simplifies servicing and allows replacement of individual elements without dismantling the entire insulation. This solution works equally well on small 50-ton machines and large 2000+ ton injection moulding machines.
Machine Bodies and Pre-Heated Moulds
For the tooling and injection moulding sector we also produce jackets for moulds pre-heated outside the machine. This solution significantly shortens mould warm-up time before production starts and reduces heat losses during the process — especially valuable in short-run production with frequent tool changes.
Custom-Designed and Sewn in Poland
Every Technic Solution insulation jacket is designed and sewn from scratch in our workshop in Poland — we do not import ready-made products and we do not work with universal “one-size-fits-all” sizing. This craftsmanship-based approach is the only way to manufacture a jacket that truly eliminates thermal bridges — the main source of energy loss in generic, off-the-shelf insulation.
European quality at competitive prices. Our customers across Europe choose us because we combine the build standards of Western European manufacturers with the cost efficiency of Polish production. Each jacket is made with high-grade ceramic fibre, fibreglass and aerogel materials, sewn by experienced specialists, and delivered with full technical support — without the price tag of UK, German or Italian competitors.
Measurements Tailored to Each Machine
Every project starts with real on-machine measurements — the circumference and width of each heater band, the gaps between them, the positions of junction boxes, temperature sensors, thermocouples and all protruding elements requiring cut-outs in the insulation. We provide a measurement template and clear instructions, so the customer can take all measurements on site without specialist equipment. Photos or sketches of the machine are equally helpful — we use them to design a precise fit from a distance.
Available Thicknesses – From the Standard 25 mm to Special Solutions
The standard thickness of our jackets is 25 mm — a value proven in practice to offer the best ratio of insulation effectiveness to available mounting space. Where space is limited (e.g. between a heater band and the machine cover), we offer thinner jackets: 15 or 20 mm, including aerogel variants — using the material with the lowest commercially available thermal conductivity. For very high temperatures or extreme thermal requirements we manufacture thicker jackets: 30, 40 or even 50 mm, or multi-layer constructions combining different materials.
How do we take measurements for thermal insulation of injection molding machines and extruders?
- Machine shutdown and cooling
- Make sure the machine is shut down and cooled down enough to remove the covers and safely take measurements.
- Dismantling the covers
- Remove any elements that restrict access to the heaters. This will make it easier to determine the actual dimensions and any obstacles.
- Measure the circumference and width of the heaters
- Measure the circumference (or diameter) of each heater and its width.
- If the heaters are far apart, it is worth providing us with an additional section not covered by the heaters (so that we can plan the appropriate allowance).
- Determining the position of the boxes and sensor outputs
- If there are electrical boxes, sensors (thermocouples) or other outputs on the heaters, provide their position and dimensions so that we can make the appropriate cutouts or holes.
- Design and sewing of the bands
- Based on the collected data, we create an individual design for each blanket, taking into account the standard thickness of 25 mm or another thickness specified by the customer. Then we sew the bands and, if necessary, make corrections to ensure simple and trouble-free assembly.
Why Choose Technic Solution Insulation Jackets
Why Choose Technic Solution Insulation Jackets
- Energy cost reduction of 20-40% on the heating system of an injection moulding machine, extruder or other industrial equipment.
- Longer heater band lifespan thanks to less frequent cycling and reduced thermal load.
- European quality at competitive prices — built to Western European standards, manufactured at Polish costs.
- Made in Poland — we design and sew in our own workshop, with no middlemen and no imports of ready-made products.
- Individual design for every machine — each jacket sewn to measure, with cut-outs for junction boxes, sensors and thermocouples.
- Operator safety — lower surface temperature of the jacket eliminates the risk of burns during machine service.
- Process temperature stability — smaller fluctuations in the barrel translate into repeatable injection and lower defect rates.
- Lower production hall temperature — less heat radiated into the environment, lower ventilation costs and better working comfort.
- Fast return on investment — one of the cheapest methods of reducing energy bills in a production plant.
- Replacement of individual jackets — in case of flooding or damage, only one element is replaced, not the entire insulation.
- Experience and technical support — we help with measurements, material selection and thickness; we provide remote support for international customers via templates, photos and specifications.
Contact Us and Request a Quote for Thermal Insulation
Every injection moulding machine, extruder, pre-heated mould or machine body requires an individual approach — that is why we always prepare quotations based on specific measurements and actual operating conditions. Get in touch, tell us about your equipment, and we will propose a solution tailored to your needs.
How to request a quote:
You will receive a quotation with a description of the solution, materials and lead time.
Write or call us — let us know the type and tonnage of the machine, the number of heater bands and the operating temperature.
Send photos of the system or measurement results (if you have them). If not — we will provide a template and instructions, and our team will support you remotely throughout the measurement process.
Contact:
Roman Cichoń — Owner phone: +48 601 636 741 e-mail: rcichon@t-solution.eu
Jakub Pionka — Sales Engineer phone: +48 788 803 391 e-mail: j.pionka@t-solution.eu
Investing in thermal insulation jackets is one of the fastest-returning decisions you can make in a production hall. The sooner you install them, the sooner you start saving.
