Ongoing Research into End-of-Life Solutions for Insulation Materials
This article is part of Plastonix’s ongoing research into end-of-life solutions for rigid insulation materials used in the construction sector. Rigid insulation materials such as extruded polystyrene (XPS), phenolic foam, and polyisocyanurate (PIR) play a critical role in building construction, but present significant challenges at end of life due to their material properties, widespread use, and limited recycling pathways.
Plastonix’s earlier research examined how extruded polystyrene (XPS) insulation behaves under controlled processing conditions, identifying potential pathways that differ from traditional disposal. Related research on phenolic foam insulation explored whether thermoset insulation materials—long considered unrecyclable—could be converted into stable powders and evaluated for potential reuse. Together, these findings provide context for the PIR research presented here.
Why Polyisocyanurate Insulation Presents Unique End-of-Life Challenges
Polyisocyanurate insulation—commonly referred to as PIR—is widely used in commercial and residential construction, particularly in roofing systems, wall assemblies, and thermal barrier applications. Its popularity stems from strong thermal performance, dimensional stability, and fire-resistant characteristics.
These same properties, however, complicate end-of-life management. PIR behaves more like a thermoset material than a typical thermoplastic. Once manufactured and cured, it does not soften or melt when reheated. As a result, PIR insulation does not integrate easily into conventional plastics recycling systems, which rely on melting and re-forming materials.
In practice, most PIR insulation removed during renovation or demolition is landfilled. Collection challenges, contamination, and a lack of established recovery pathways further limit alternatives.
Research Objective: Evaluating PIR Material Behavior
Plastonix initiated this research to better understand how PIR insulation behaves when processed under controlled laboratory conditions using its proprietary plastic recycling technology.
The objective was not to produce a finished product or to claim recyclability, but rather to observe material behavior: how PIR responds physically when processed, and whether that behavior could support alternative end-of-life pathways.
This research is exploratory in nature and focuses on early-stage observations rather than commercial outcomes. Additional background on the Plastonix Technology being evaluated, including the role of Transformix™ within that process, is available on the Plastonix website.
Preliminary Laboratory Findings (Part 1): PIR Powder Formation
In early laboratory testing, Plastonix observed that PIR insulation, when processed in the presence of Transformix™, could be converted into a powdered state.
Unlike phenolic foam—which converted into a very fine powder in earlier research—the PIR material formed a more granular powder. The resulting material was dry and free-flowing, but visibly coarser in structure.
This distinction is important. Powder characteristics influence handling, blending behavior, and downstream evaluation. A granular powder may behave differently than a fine powder when combined with other materials or subjected to further processing.
At this stage, Plastonix is reporting only what was observed: PIR can be processed into a powdered form under specific conditions, and that powder exhibits a granular structure.
Preliminary Laboratory Findings (Part 2): Blending PIR Powder with Film Plastics
Following the powder formation observed in Part 1, Plastonix conducted additional testing to explore whether the granular PIR powder could be blended with other types of plastic materials. In this phase, the PIR powder was blended with film plastics under controlled conditions. The resulting material formed a solid plastic material that could be physically handled and further evaluated.
These observations suggest that powdered PIR may be compatible with certain types of plastic materials when used as a material input. Importantly, this does not imply recycling PIR back into insulation products, nor does it suggest specific end-use applications.
The outcome is best described as the materials being able to blend together, indicating potential for repurposing rather than definitive recycling pathways.
How PIR Behavior Compares with Phenolic Foam and XPS
Comparing PIR behavior with findings from earlier articles in this series highlights why insulation materials must be evaluated individually.
- Phenolic foam converted into a fine powder and was successfully blended into polyurethane foam formulations without degrading performance.
- XPS insulation underwent densification, collapsing its foam structure into a rigid material more compatible with downstream handling.
- PIR insulation, by contrast, formed a granular powder and was able to be blended with film plastics.
These differences underscore that “foam” is not a single category from an end-of-life perspective. Material chemistry, structure, and processing behavior vary significantly, and recovery strategies must account for those differences.
Interpreting the Results: What This Research Does and Does Not Show
These early findings suggest that PIR insulation may be capable of participating in alternative end-of-life pathways focused on material reuse and value retention rather than disposal.
At the same time, this research does not demonstrate:
- Closed-loop recycling of PIR into new insulation
- Commercial readiness or scalability
- Environmental benefit claims at this stage
Plastonix emphasizes that these results are preliminary and should be interpreted as part of an ongoing evaluation process rather than a final conclusion.
Path Forward
Plastonix will continue laboratory testing to assess the consistency of PIR powder formation and blending behavior across additional PIR insulation materials and a wider range of plastic materials.
Future work will focus on confirming whether these results can be repeated, evaluating material stability over time, and understanding how the combined materials behave under different conditions. These steps are necessary before broader conclusions can be drawn.
Continuing Research and Evaluation
The findings described in this article reflect ongoing laboratory and applied research by Plastonix. All observations remain subject to further validation as testing continues.
PIR insulation research forms part of a broader roadmap examining multiple construction insulation materials under comparable conditions. Further details on the underlying Plastonix Technology supporting this work, and how it is being evaluated across different materials, are available on the Plastonix website.
About Plastonix
Plastonix is a plastic recycling technology company focused on making large-scale recycling viable. The company is the manufacturer of Transformix™, a proprietary processing agent designed to enable the recovery and reuse of plastics that are difficult to recycle at scale. Plastonix conducts laboratory and applied research in support of the ongoing development and evaluation of its technology and related material pathways. Transformix™ and PX42™ are proprietary Plastonix plastic recycling technologies. For inquiries related to this research or Plastonix’s technology development, please contact us. Research findings are preliminary and subject to further validation.