BLACK CAT INSULATION TECHNICAL JSC INVESTS IN CNC FABRIC CUTTING MACHINE FOR FABRICATION REMOVABLE INSULATION PILLOWS

In the context of increasing demand for thermal insulation efficiency across industrial sectors, manufacturers of insulation materials are required to invest heavily in equipment and technological upgrades. Black Cat Insulation Technical JSC has recently commissioned a specialized laser-based CNC fabric cutting machine to support the fabrication of removable insulation pillows for various equipment applications, particularly in gas turbines and steam turbines at thermal power plants. This investment aims to enhance precision, shorten production lead time, and better meet the technical requirements of the market.

1. The Growing Trend of Using Removable Insulation Pillows in Industry

Removable insulation pillows are increasingly used across various industrial facilities such as thermal power plants, chemical plants, cement factories, refineries, and petrochemical plants, as well as food & beverage manufacturing, and other systems that require high-performance thermal insulation

These insulation pillows are constructed from multiple layers of specialized materials, including:

• Outer heat-resistant fabrics (Silica fabric, Fiberglass fabric, Ceramic fabric, etc.)
• Internal insulation layers (glass wool, ceramic fiber, mineral wool, or other insulation materials).
• Supporting fastening accessories.

A major advantage of removable insulation pillows is their flexibility in installation and removal, enabling convenient equipment maintenance while minimizing heat loss at components such as flanges, valves, pumps, pipelines, and other equipment with complex geometries.

In thermal power plants, for example, gas turbines and steam turbines require specialized insulation due to high operating temperatures, complex shapes, and the need to maintain stable heat retention to ensure unit efficiency. This creates a demand for precise material cutting. To achieve consistent insulation performance, fabrication must meet high accuracy requirements—especially at curved sections and complex contours. This is why fabrication companies rely on specialized CNC cutting technology.

2. Insulation Requirements for Gas and Steam Turbine Assemblies

Gas and steam turbine assemblies operate under high temperatures and demanding conditions; therefore, insulation pillows used in these areas must meet the following criteria:

• Withstand temperatures up to 1000°C, depending on the specific location.
• Conform closely to the turbine casing, expansion areas, bolts, and inspection ports.
• Eliminate gaps to ensure stable thermal retention
• Allow easy removal and reinstallation during periodic maintenance
• Avoid interference with surrounding structures or instrumentation

To meet these requirements, the outer fabric typically consists of silica fabric, PTFE-coated fiberglass, or ceramic fabric, while the insulation layer commonly uses ceramic fiber. These materials require the use of specialized cutting machines to achieve the necessary precision.

3. CNC Fabric Cutting Machine – New Investment by Black Cat Insulation Technical JSC

To meet the technical requirements for the production of removable insulation pillows, Black Cat JSC has invested in a specialized CNC fabric-cutting system. The equipment is engineered for heat-resistant materials and optimized for industrial insulation applications.

3.1. Technical Features of the CNC Machine

The CNC machine is equipped with the following capabilities:

• Large cutting table (W1200 × L3000), allowing the processing of various material sizes.
• Laser CNC cutting technology is suitable for non-metallic, heat-resistant materials such as fiberglass fabric, silica fabric, and ceramic fabric. These materials typically possess high stiffness, strong fiber structure, and high surface adhesion—making them difficult to cut manually.
• High-precision cutting of curved lines and complex contours.
• Integrated material-holding system to prevent shifting during the cutting process.

With these features, the CNC machine delivers smooth and consistent cuts, ensuring that every insulation pillow component meets the exact design dimensions.

3.2. Efficiency Improvements in the Fabrication Process

Integrating CNC technology into production brings several key benefits:

• Shortened fabrication time, especially in the fabric-cutting stage, which accounts for a significant portion of the insulation pillow manufacturing process
• Consistent product quality, reducing dimensional deviations between batches.
• Optimized material usage, minimizing waste and associated risks.
• Increased productivity, particularly for large-volume orders.
• Enhanced capability to fabricate insulation pillows for complex components such as globe valves, butterfly valves, turbines, and curved or irregular surfaces.

As a result, the company is now able to meet orders with short delivery schedules while satisfying the high technical standards required in major industrial projects.

3.3. Removable Insulation Pillow Fabrication Process at Black Cat JSC

Black Cat JSC applies a structured fabrication process that includes the following steps:

• On-site survey and measurement: Actual dimensions and operating conditions are collected directly at the project site.
• Design and modeling: Based on field data, the engineering team creates the insulation pillow model using specialized software, defining stitch lines, material thickness, and contour profiles
• CNC material cutting: The CNC machine cuts the outer fabric precisely according to the designed contour, ensuring the pillow fits tightly around the equipment without gaps that could cause heat loss.
• Insulation material preparation: The inner insulation layer is cut to the corresponding size, ensuring proper thickness and compression ratio.
• Final stitching and quality inspection: All components are stitched using heat-resistant thread. After completion, each pillow is inspected for dimensional accuracy, sealing, and proper fit on the equipment before packaging.

4. Reference Projects Completed by Black Cat JSC

Black Cat Insulation Technical JSC has fabricated and installed removable insulation pillows for numerous projects.

The company supplied products and executed insulation repair works for gas turbine and steam turbine units at Ca Mau 1 & 2 Gas Power Plants. Some images from the project include:

Supply of products and execution of insulation repair works for gas turbines in the Major Overhaul Project of Nhon Trach 2 Thermal Power Plant

Supply of products and insulation installation services for the Heineken Da Nang Brewery Project.

Investing in the CNC fabric cutting machine has enabled Black Cat JSC to enhance its production capacity for removable insulation pillows, particularly for technically demanding applications such as gas and steam turbines in thermal power plants. CNC technology helps improve precision, reduce fabrication time, and ensure product consistency throughout equipment operation. This represents a significant step forward in the company’s technology upgrade roadmap and its ongoing expansion of fabrication capabilities.

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