Mai 30, 2024

Insulo: Redefining Precision and Efficiency in Gasket Solutions


With Insulo, a leader in technical foam solutions, we partnered with a prominent HVAC manufacturer to develop a groundbreaking gasket solution for display screens. This case study highlights our innovative approach, which resulted in a remarkable 92% reduction in scrap rate, positively impacting packaging, waste, and overall cost.


The customer required a high-quality gasket to be placed between a display and their transparent cover, ensuring protection against dust and humidity. The conventional rectangular-shaped gaskets were effective but generated significant waste during production.


By leveraging advanced tooling and co-designing with the customer, Insulo developed a precision-engineered gasket that maintained the same high standards of quality while drastically reducing waste. This final solution was achieved after performing various trials to ensure optimal performance and efficiency.


  1. Co-Design Collaboration: Worked closely with the customer’s engineering team to understand the specific requirements and constraints.
  2. Tooling Optimization: Invested in state-of-the-art tooling technology to enhance production precision and minimize material waste.
  3. Prototyping and Testing: Created prototypes for different trials and subjected them to rigorous testing to ensure they met all performance criteria for dust and water vapor protection.


  • Scrap Rate Reduction: Achieved a 92% reduction in scrap rate, significantly lowering material waste.
  • Cost Savings: Reduced production costs due to decreased waste and improved efficiency.
  • Environmental Impact: Minimized packaging and waste, contributing to a more sustainable manufacturing process.
  • Quality Maintenance: Ensured the new gasket solution maintained the same quality standards, effectively protecting the display screens.


Insulo’s innovative approach and commitment to co-engineering solutions with our customers have set a new benchmark. This project exemplifies our ability to deliver high-quality, cost-effective, and environmentally sustainable solutions.