Wednesday, July 9, 2025
Stora Enso has made significant strides in transforming insulation materials in the ever-evolving world of sustainable construction. With a focus on innovation and sustainability, Damiano Della Lunga and his team at Stora Enso have pioneered the development of a formaldehyde-free, bio-based binder for mineral wool insulation. This new technology is not only aligned with upcoming regulatory changes but also offers long-term environmental and economic benefits for the construction industry.
A creative move away from formaldehyde in insulation
Damiano Della Lunga, a research and development (R&D) specialist at Stora Enso, emphasised the importance of choosing the right binder for insulation production. For Damiano and his team, the goal was clear: to find a bio-based binder that could replicate the performance of traditional formaldehyde-based adhesives while adhering to future regulations. As the construction industry faces increasing scrutiny over the use of volatile organic compounds (VOCs), particularly formaldehyde, Stora Enso’s breakthrough offers a timely solution.
Formaldehyde, a chemical commonly used in insulation materials, has been flagged for its potential health hazards and environmental impact. In anticipation of stricter regulations set to take effect in 2026, Stora Enso’s team sought a more sustainable alternative. By replacing the conventional phenol-formaldehyde binder with NeoLigno®, a thermosetting resin derived from renewable resources, the company has positioned itself as a leader in environmentally friendly construction solutions.
The advantages of NeoLigno® for the economy and environment
One of the primary advantages of switching to a formaldehyde-free binder is the elimination of harmful emissions. Formaldehyde and aldehyde emissions not only pose risks to human health but also incur significant costs for manufacturers, especially in the form of fines for non-compliance. According to Della Lunga, the adoption of NeoLigno® allows manufacturers to avoid these costly penalties while also positioning themselves as environmentally responsible players in the market. “By eliminating formaldehyde, we are not only ensuring regulatory compliance but also realising significant cost savings,” notes Della Lunga. “Failure to meet emission standards can lead to fines or, in the worst case, a shutdown of operations. Compliance not only safeguards against these risks but also enhances our market position, as consumers and clients increasingly demand renewable, bio-based, and certified products.”
A reliable alliance with Stora Enso
In 2020, Della Lunga and his team partnered with Stora Enso to explore innovative binding agents for their insulation products. Stora Enso’s NeoLigno® was identified as an ideal solution due to its cost-neutral nature and its ability to meet both current and future regulatory requirements. NeoLigno® is a thermosetting binder that offers comparable performance to traditional resin, but with a key difference: it sets at significantly lower temperatures. This lower processing temperature—20 to 30 degrees Celsius lower than its predecessors—results in reduced energy consumption during manufacturing, further enhancing the cost-effectiveness of the solution. “We were looking for a binder that could be used both for indoor and outdoor insulation. NeoLigno® worked exceptionally well in this regard, providing the same high performance for outdoor applications where other bio-based binders often fall short,” Della Lunga explains.
Breaking past obstacles with bio-based binders
A common challenge with bio-based binders is their resistance to environmental factors, such as humidity and biological degradation. Many bio-based alternatives struggle to maintain their structural integrity in exterior insulation applications, which can complicate logistics and add to costs. However, NeoLigno® has been proven to be durable and reliable even in harsh outdoor conditions, making it a versatile solution for both indoor and outdoor applications. “Some bio-based binders have issues with humidity resistance and biological degradation. This means that manufacturers often need to use different binders for indoor and outdoor insulation, which complicates the production process,” Della Lunga notes. “With NeoLigno®, we can use the same binder across all insulation products, streamlining production and reducing costs.”
A team-based innovation approach
The successful development of NeoLigno® was not a solitary endeavor but a collaborative effort between Stora Enso’s research team and Della Lunga’s group. The close working relationship between the two teams was crucial in fine-tuning the binder’s formulation and ensuring its success in both laboratory and real-world settings. “Having a trusted partner with expertise in both materials science and industrial applications was invaluable. Stora Enso’s team provided essential insights into the chemistry of NeoLigno® and helped us address any challenges that arose during trials,” Della Lunga reflects. “This collaboration was critical to the success of the project.”
As the construction industry faces increasing regulatory pressure to reduce the use of hazardous chemicals, Della Lunga predicts that the trend toward bio-based and formaldehyde-free solutions will continue to gain momentum. “We can foresee a future where all aldehydes are banned from use in insulation products, and our switch to NeoLigno® ensures that we will be fully compliant with these evolving standards,” he says. “Other manufacturers will have to invest significant resources into monitoring and adjusting their processes to stay compliant, but with NeoLigno®, we are ahead of the curve.”
The six-step process to innovation
Della Lunga’s team employed a rigorous, six-step process to develop and implement NeoLigno® in their insulation products. This process, which includes extensive testing, formulation adjustments, and collaboration with experts, ensures that the binder meets both technical and regulatory standards.
By adhering to this methodical approach, Della Lunga and his team have successfully integrated NeoLigno® into their production processes, offering a sustainable, cost-effective solution for the insulation industry.
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