In today’s economic landscape, businesses are constantly looking for new ways to reduce operational costs while maintaining performance and sustainability. One often-overlooked area with significant savings potential is energy efficiency—particularly in building insulation. A compelling example of this comes from a mid-sized manufacturing company that dramatically slashed its energy bills using Open-Cell Foam insulation and a cutting-edge application technique called platinum spray.

The Energy Cost Challenge

The company, located in the Midwest, operates a 40,000-square-foot facility housing production equipment, office space, and storage. As energy prices continued to rise, especially during peak summer and winter months, the company's heating and cooling costs ballooned to over $120,000 annually. With margins tightening, executives knew it was time to take a hard look at how their building managed energy.

An energy audit revealed several inefficiencies, the most significant of which was poor insulation. The building's original fiberglass insulation had deteriorated over time and was no longer providing adequate thermal resistance. Air leakage, inconsistent internal temperatures, and overworked HVAC systems were all contributing to skyrocketing energy use.

Exploring Better Insulation Options

To address these issues, the company brought in a building performance consultant to evaluate new insulation options. After weighing the pros and cons of traditional fiberglass, rigid foam boards, and spray foam, one solution stood out: Open-Cell Foam.

Open-Cell Foam is a type of spray polyurethane foam (SPF) known for its excellent air-sealing properties and high R-value per inch. Unlike closed-cell foam, open-cell is softer, more flexible, and significantly lighter. It expands rapidly upon application, filling gaps, cracks, and hard-to-reach spaces with ease.

But what sealed the deal—pun intended—was the introduction of platinum spray, a specialized technique and formula that enhances the performance and application of Open-Cell Foam.

What Is Platinum Spray?

Platinum spray refers to a proprietary formulation and spraying process that improves foam adhesion, expansion, and uniformity. It allows the foam to cure more evenly, stick better to various surfaces (including metal and concrete), and create a more continuous thermal envelope. For commercial buildings like this one, platinum spray delivers faster installation with fewer voids, less waste, and better long-term durability.

The Installation Process

The company scheduled the retrofit during a two-week production lull. Certified installers prepped the building, removed degraded fiberglass batts, and sealed off sensitive areas. They then applied Open-Cell Foam using the platinum spray method, focusing on the roof deck, wall cavities, and hard-to-access crawl spaces.

The foam expanded instantly, creating a seamless insulation layer that tightly adhered to every surface. Thanks to the platinum spray’s advanced properties, the application team achieved a consistent thickness and complete coverage in record time—three days ahead of schedule.

Immediate Results

The impact was noticeable almost immediately. Within days of completing the retrofit, employees reported a more consistent and comfortable indoor climate. The temperature no longer fluctuated drastically between different parts of the building. The HVAC systems cycled on and off less frequently, reducing wear and tear.

When the first full-month utility bill came in, the results were jaw-dropping: a 23% reduction in energy consumption. Over the next six months, the company saved nearly $15,000 on heating and cooling alone. Projections indicated a full return on investment in just under three years.

Long-Term Benefits

The benefits of the Open-Cell Foam and platinum spray solution didn’t stop at energy savings:

1. Improved Indoor Air Quality

Because the foam filled cracks and gaps so thoroughly, the building experienced significantly less infiltration of outdoor allergens, pollutants, and humidity—leading to a healthier work environment.

2. Sound Insulation

Open-Cell Foam is excellent at dampening sound. The company reported noticeable reductions in outside noise and internal echoes, which improved working conditions in the office and production areas.

3. Structural Reinforcement

Although open-cell isn’t as rigid as closed-cell foam, the platinum spray-enhanced formulation provided added stability to the building envelope, especially in roof and wall assemblies.

4. Sustainability and Compliance

With stricter building codes and rising demand for green certifications, this upgrade positioned the company well for future compliance requirements and potential sustainability certifications like LEED.

Lessons for Other Businesses

This case offers a few critical takeaways for any business looking to reduce energy costs:

• Don’t overlook insulation. It might seem like a basic part of your building, but poor insulation can be a silent killer for energy efficiency.

• Choose the right material. Open-Cell Foam offers unique benefits that can outperform traditional materials in the right conditions.

• Invest in the right application method. Techniques like platinum spray may cost slightly more upfront but yield significantly better performance and ROI.

• Track and measure results. Energy savings should be verified with real data. Utility bill analysis, temperature monitoring, and HVAC performance tracking all help validate the benefits.

Is Open-Cell Foam Right for You?

While this company’s success story highlights the power of Open-Cell Foam and platinum spray, it’s not a one-size-fits-all solution. Buildings in extremely humid or flood-prone areas may benefit more from closed-cell foam due to its moisture barrier properties. However, for many commercial and industrial buildings, especially those needing air sealing and thermal control, open-cell solutions can be a game-changer.

Conclusion

As businesses navigate the dual pressures of rising costs and sustainability demands, smart building upgrades like spray foam insulation can deliver surprising returns. For this manufacturing company, switching to Open-Cell Foam with platinum spray was not just an improvement—it was a strategic move that paid off both financially and environmentally.