Design of plastic parts adapted to the challenges of the HVAC sector

The HVAC sector faces increasingly stringent requirements for energy efficiency, reliability, and durability. Even under demanding operating conditions, particularly for outdoor units exposed to harsh climates, HVAC systems must ensure indoor comfort while minimizing heat loss, maintaining optimal air circulation, and reducing noise.

At Knauf Industries, we develop custom-made technical parts that integrate several essential functions within a single component: thermal insulation, acoustic attenuation, mechanical resistance, and simplified assembly.

We work closely with your teams to design solutions tailored to the constraints of each piece of equipment. Thanks to the design freedom offered by cellular materials, a single component can incorporate cable passages, mounting brackets, and dedicated insulation zones.

The main advantages of our solutions

At Knauf Industries, we develop custom-made plastic parts for the HVAC sector that deliver numerous technical benefits in terms of both energy performance and user comfort.

Lightweight yet robust components

The cellular materials used in our solutions allow us to design parts that are both very lightweight and resistant to mechanical stress.

Thanks to their lightweight design, our solutions facilitate equipment handling, simplify installation, and reduce logistics costs. Despite their low weight, our plastic parts offer excellent resistance to impacts, humidity, and chemicals, ensuring optimal durability even in challenging environments.

Energy efficiency optimization

This is one of the main challenges of HVAC systems: reducing heat loss. And it so happens that our insulating parts made of EPP and EPS limit heat transfer between components and therefore improve the overall efficiency of the equipment.

Our custom-made plastic parts for the HVAC sector enable manufacturers to offer higher-performing equipment that meets increasingly stringent energy efficiency requirements.

Insulation improvement

Cellular foams possess natural thermal and acoustic insulation properties. They thus help to reduce noise generated by ventilation systems or compressors, while also limiting vibrations.

Condensation resistance

Condensation is a common occurrence in ventilation and air conditioning systems. Our insulating components made of EPP and EPS help prevent condensation and ensure a good seal for the equipment. This, in turn, reduces the risk of corrosion and extends the lifespan of the installations.

Take advantage of these benefits

We produce parts for...

Knauf Industries' solutions are used in many HVAC systems in the residential, commercial and industrial sectors.

Heat pumps

The design of heat pumps requires insulating components capable of limiting energy losses and dampening vibrations.

In this respect, we manufacture, among other things:

Covers and insulation elements for indoor and outdoor units;
Frames and structures for heat pumps;
Hydraulic modules or technical supports.

Heating systems

In heating equipment, thermal insulation plays a predominant role in maintaining temperature and limiting energy losses.

Our solutions are used for:

Insulation of water heaters and thermodynamic water heaters;
Hydraulic manifolds and connections;
Heat distribution systems.

Air conditioning and refrigeration systems

Air conditioning and refrigeration equipment requires components capable of withstanding temperature variations.

Knauf Industries develops, in particular:

Condensate trays;
Structural parts for fan coil units and terminal units;
Insulating components for ventilation and heat recovery systems.

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The materials we use

For the manufacture of custom parts for the HVAC sector, we mainly use cellular foams which are known to offer excellent insulation and resistance performance.

EPP (expanded polypropylene)

Approximately 95% air
Excellent thermal and acoustic insulation
High mechanical resistance
Vibration absorption
Durable and recyclable material

EPS (expanded polystyrene)

Up to 98% air
Very good thermal insulation
Lightweight and economical material
Wide range of density depending on technical requirements
Recyclable through appropriate channels

In line with the principles of the circular economy, these materials can be replaced by recycled materials or materials from renewable sources in order to reduce the environmental impact of equipment.

Case study

FLOWAIR replaced the traditional steel casings of its devices with EPP components, drastically reducing the device's weight. Manufacturing and transporting equipment with these components resulted in a nearly 50% reduction in CO₂ emissions compared to equipment with steel frames.

Read the case study

Request a quote

Are you developing HVAC equipment and looking for custom-made technical parts to improve its performance and reliability?

The Knauf Industries team will support you throughout your project, from needs analysis and technical design to prototyping and industrialisation.

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Custom-made parts for the HVAC sector