Mica Insulation, Electrical and Automotive Industry Blog

The future of industrial insulation

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Key trends shaping what comes next

Industrial insulation does a lot of heavy lifting, even if it’s rarely noticed. It protects people, processes and equipment and allows systems to run reliably.

As industries move towards higher temperatures and tougher sustainability targets, insulation materials are evolving to meet new challenges. So, what does the future of industrial insulation look like? Here are the key trends shaping what comes next.

Lighter insulation without compromising performance

Many industries are working to reduce weight wherever possible. In aerospace, automotive and battery systems, lighter components improve efficiency and help equipment last longer.

Insulation is no exception. New materials are replacing older, heavier options, offering the same level of protection in a thinner, lighter form. Mica-based laminates and microporous insulation work well here, especially in compact designs where space and weight really matter.

Meeting the demand for higher temperature resistance

Industrial processes are running hotter than ever before. Foundries, furnaces, petrochemical plants and glass production all rely on insulation that can handle extreme heat for long periods of time.

Future insulation needs to stay stable at these temperatures without breaking down or becoming unsafe. Mica naturally performs well in hot environments, continuing to provide heat resistance and fire protection when other materials struggle. Better high-temperature insulation also helps reduce heat loss, which can lower energy use and running costs.

Sustainability and recyclable insulation materials

Pressure to cut emissions, waste, and energy use is growing across every industry. Insulation is playing a part by lasting longer, using materials more efficiently and reducing the need for frequent replacement.

Natural materials like mica can support these goals. When responsibly sourced, mica offers long service life and reliable performance, helping businesses reduce waste and work towards net-zero targets.

Smarter insulation for improved safety

Insulation is starting to work alongside monitoring systems that track temperature and performance during operation.

This is particularly useful in furnaces, battery systems and continuous processes. Early signs of overheating or insulation damage can improve safety, prevent unplanned shutdowns and allow maintenance to be planned rather than reactive. As monitoring becomes more common, insulation will increasingly be designed to support these systems.

Supporting electrification and battery systems

The move towards electrification is changing what insulation needs to do. Batteries, power electronics and electric vehicles produce a lot of heat and operate at high voltages, often in very tight spaces.

Insulation in these systems must control heat, provide electrical separation and offer fire protection all at the same time. Mica-based insulation is widely used here because it combines strong electrical insulation with high temperature resistance.

Fire protection remains a priority

Fire protection remains a key concern across many industries. Insulation materials must perform under fire conditions without releasing harmful fumes or failing when they are needed most.

Mica-based and microporous insulation is commonly used in fire doors, cable protection, data recorders and other safety-critical areas. Ongoing development is focused on improving fire performance while reducing thickness and overall weight.

The value of bespoke insulation solutions

As industrial systems become more complex, standard insulation products don’t always fit the job. Many applications now need insulation designed around specific temperatures and safety requirements.

Custom mica components and laminates allow engineers to get the right balance of performance, reliability, and cost, even in demanding conditions.

The future is lighter, stronger and more sustainable

The future of industrial insulation is lighter, more efficient, and better suited to modern demands, while still quietly doing its job in the background. As industries evolve, insulation will remain essential to safety and reliable long-term operation.

For businesses looking to improve efficiency, strengthen safety and stay ready for what comes next, insulation deserves far more attention than it usually gets. Call 020 8520 2248 or contact us via the website to find out more.

How advanced insulation protects both people and infrastructure

Blogs

When an industrial furnace runs too hot or an EV battery begins to fail, in environments like these, problems rarely stay small. Heat builds up and electrical systems come under strain. Left unchecked, that combination can quickly put people and equipment at risk.

This is where advanced insulation makes a difference. Mica-based insulation works in the background, stopping minor issues from turning into serious failures.

Here’s how mica-based insulation protects both people and the critical systems we depend on every day.

What makes mica valuable?

Mica has a set of properties that make it especially suited to demanding applications. It can withstand extreme temperatures where many other materials break down, providing reliable protection. It’s also electrically non-conductive and remains stable under high voltage.

On top of that, mica holds up well under mechanical stress, vibrations, rapid temperature changes and exposure to chemicals. It can be used on its own or combined with other materials and manufactured in many different forms – from flat sheets and tubes to high-performance panels.

How mica works behind the scenes

At Elmelin, we don’t just offer standard insulation sheets and hope they’ll do the job. Every project is backed by decades of manufacturing experience and strict quality control.

We also work with advanced microporous insulation, which can be combined with mica to deliver excellent thermal performance where space is tight, weight matters or temperatures are extreme.

All of our manufacturing processes follow strict quality and safety standards, backed by our ISO 9001:2015 accreditation, ensuring reliability and compliance across industries.

Where protection matters most

Mica-based insulation is used across many industries, often in places most people never see.

Industrial furnaces, foundries and steel

In foundries and steelworks, furnaces operate at incredibly high temperatures. Mica laminates and microporous boards help keep linings stable and extend the life of equipment. Special safety layers can even provide early warning signs of wear or damage before a failure occurs.

Automotive and electric vehicle industry

In the automotive world, and especially in electric vehicles, managing heat and high voltage is critical. Rigid mica and composite insulation help control battery temperatures and maintain electrical safety, reducing the risk of overheating or thermal runaway.

Aerospace and transport

Aerospace and transport applications demand materials that are lightweight, dependable and able to perform under extreme conditions. Mica is used as a thermal barrier to protect sensitive electronics and data recorders. In mass transport and other high-risk settings, it also plays an important role in fire protection and passenger safety.

Power electronics and electrical systems

Power electronics and electrical systems rely on insulation that can cope with heat and electrical stress over long periods of time. Mica-based tubes and components provide long-lasting protection in equipment where failure isn’t an option.

Consumer appliances and everyday equipment

Even in everyday appliances, like ovens, kettles, and hairdryers, mica insulation helps ensure electrical safety and thermal stability. It allows manufacturers to meet strict safety standards without sacrificing performance or design.

Compliance and responsibility

Meeting safety standards isn’t optional. Fire protection rules and industrial requirements all depend on insulation that performs reliably over time.

Mica-based solutions help organisations meet these demands by providing fire-resistant, non-combustible materials, dependable electrical insulation for high-voltage systems, and thermal stability that prevents overheating and mechanical damage. They also support a quality-focused supply chain, backed by certified manufacturing processes.

Thinking about your system

If your system runs hot, carries high voltage, or needs to perform reliably for decades under stress, insulation shouldn’t be an afterthought. In many cases, mica-based or microporous insulation is the hidden factor that makes long-term safety and stability possible.

Invisible material, visible impact

You may never see insulation at work, but its impact is very real. Advanced mica-based materials help protect people, preserve infrastructure, support compliance, and keep systems running safely under extreme conditions.

If you’re responsible for a project where temperature, electricity, safety, or regulation matters, choosing the right insulation shouldn’t be an afterthought.

Get in touch

At Elmelin, we’ve spent more than a century turning a humble mineral into powerful protection. What started in 1912 as a small mica-processing site in Walthamstow, London, has evolved into a global leader in high-performance thermal and electrical insulation.

Today, our materials help safeguard everything from industrial furnaces and EV battery packs to aerospace systems and heavy-duty machinery. Our solutions work quietly in the background, keeping people safe and equipment running smoothly.

To discuss how mica could help your project meet safety, performance and compliance goals, get in touch with the team at Elmelin.

Call 020 8520 2248 or contact us via the website – we’re here to help.

The hidden heroes of insulation

Consumer Appliances

Opening your dishwasher, switching on your hairdryer, charging your electric vehicle – you probably don’t think about insulation. Yet, hidden behind sleek designs and digital displays, advanced insulation materials quietly make our lives safer and more sustainable.

Among these, mica and microporous insulation stand out as silent heroes of modern technology, ensuring reliability from domestic appliances to the most advanced electric vehicle battery packs.

At Elmelin, we’ve been perfecting the science of insulation since 1912. Our origins go back to a mica processing site in Walthamstow, London, where our expertise in heat and electrical management first took shape. Over a century later, we’ve evolved into one of the UK’s leading manufacturers of advanced insulation materials.

And though these materials often go unseen, they’re the hidden heroes at the heart of countless everyday technologies.

The unsung hero of safety

Mica is an extraordinary material. It’s naturally heat-resistant, electrically insulating and mechanically strong – all properties that make it indispensable in environments where safety and performance come first.

It doesn’t melt, burn or conduct electricity. That means it can sit next to red-hot heating elements or high-voltage components and still protect the surrounding systems. From electric motors and toasters to high-voltage capacitors and stoves, mica insulation quietly ensures that heat and energy are contained and controlled.

Microporous insulation takes that protection to another level. Made from ultra-fine materials, it traps air in microscopic pockets, drastically reducing heat transfer. The result? Systems that stay cooler for longer, use less energy and perform more efficiently.

Together, mica and microporous materials are the invisible backbone of safety and sustainability in modern living.

Making modern appliances safer

Think about the everyday appliances you rely on. Dishwashers, ovens, stoves, hairdryers, kettles – all of them generate significant heat or carry electric currents. Without proper insulation, these appliances would not only waste energy but also pose serious safety risks.

Dishwashers and Ovens

Our mica sheets and laminates help protect the inner workings of high-temperature appliances. Inside ovens, mica acts as a thermal shield, preventing heat from damaging wiring and control systems. In dishwashers, it serves as electrical insulation, ensuring components remain protected from moisture and current leaks.

Stoves and Heaters

In electric stoves and space heaters, mica forms the core insulation layer between the heating element and the metal casing. It maintains consistent heat distribution while keeping the external surfaces safe to touch – improving both performance and user safety.

Hairdryers and Small Appliances

Inside your hairdryer, there’s a strip of mica that insulates the heating coil. It allows the air to heat quickly without the risk of electrical arcing. This same principle applies to toasters, irons and electric kettles – where mica’s unique combination of temperature resistance and dielectric strength ensures reliable, long-term performance.

Powering the world behind the scenes

High Voltage Capacitors and Electric Motors

Mica is widely used in high-voltage capacitors, where it provides the dielectric barrier needed to handle thousands of volts. Its consistent electrical stability helps prevent failures, protecting systems from surges and ensuring continuous power delivery.

In electric motors, mica-based components such as tubes and laminates act as insulators for windings and stators. They protect against overheating, prevent short circuits and increase overall efficiency, which is essential for everything from washing machines to industrial equipment.

Thermal and Electrical Components

Beyond mica, our Elmtherm Microporous Insulation offers high-performance thermal protection for industries and technologies that demand extreme precision. It’s lightweight, durable and capable of handling temperatures where conventional insulation breaks down – perfect for compact systems where every millimetre counts.

Our products

Compression Pads Plus

EV batteries face intense thermal and mechanical demands. As battery cells charge and discharge, they expand, contract and generate heat. Our Compression Pads Plus maintain consistent mechanical pressure across battery packs while providing thermal and electrical insulation. This prevents deformation, reduces the risk of thermal runaway and improves both performance and safety.

Mica Roll Laminates

In coreless induction furnaces, maintaining precise temperature control is critical for consistent casting and production. Our Mica Roll Laminates, part of the Elmelec range, act as a thermal and electrical barrier between the induction coil and refractory crucible, protecting both components and extending furnace life.

Mica Sheets

Mica sheets are among the most adaptable insulation materials in existence. Available in both rigid and flexible forms, they provide dependable thermal and electrical insulation in everything from heavy industrial furnaces to household appliances.

Rigid Mica Sheets are used in heaters, furnaces, hairdryers, tumble dryers and toasters, offering reliable insulation at temperatures up to 1200°C (MR SSP grade) and 1000°C (MR SSM grade). They resist repeated heating and cooling cycles without degradation, making them ideal for long-term use in harsh environments.

You might not see our materials, but you experience their benefits every day:

• Dishwashers rely on mica insulation to protect heating elements from water and electrical faults.
• Stoves and ovens use mica components to maintain even temperatures and prevent short circuits.
• Hairdryers depend on mica plates to withstand continuous heating, ensuring safe operation.
• Electric motors in everything from washing machines to industrial equipment use mica tubes and composites for reliable electrical insulation.
• High-voltage capacitors use mica for its superior dielectric properties, ensuring consistent power delivery.

The hidden heroes revealed

From the glow of an oven element to the charge inside an electric vehicle, mica and microporous insulation play an invisible but irreplaceable role in modern life. They’re the materials that protect, stabilise and extend the performance of everything around us.

Ready to learn more? Please call our experienced team on 020 8520 2248 today.

How Mica insulation powers the Automotive and Aerospace industries

Mica

When you think of electric cars or modern aircraft, you probably picture sleek designs, advanced batteries or cutting-edge electronics. But behind all that exciting innovation, Mica insulation is keeping everything running safely.

Mica is a naturally remarkable material, it can withstand extreme heat, insulate against electricity and stay strong under pressure. It might not make the headlines but it plays a key part in keeping EV battery packs safe, flight recorders secure and aircraft systems protected.

At Elmelin, we’ve spent decades turning this material into practical solutions that engineers and manufacturers can rely on. Our work helps make vehicles and aircraft safer and built to last. Let us explain how Mica powers the Automotive and Aerospace industries and its impact.

Why Mica Matters

Mica’s natural properties are extraordinary. It’s heat-resistant, non-combustible, mechanically stable, and an excellent electrical insulator. These qualities make it ideal for applications where safety and performance are non-negotiable, from high-voltage EV batteries to aircraft flight recorders.

At Elmelin, we transform mica into both pure and combined insulation solutions, tailored to meet the needs of each industry. Over the years, we’ve also diversified our offering beyond mica – providing microporous insulation, gasketing and waterproofing applications.

Powering the Automotive Industry

The automotive sector is undergoing a transformation unlike any we’ve seen before. The shift toward electric and hybrid vehicles is driving the need for advanced safety measures and sustainable solutions.

Mica-based insulation plays an incredibly important part in supporting this transformation. Here’s how:

Battery Pack Insulation

EV batteries generate significant heat during operation and charging. Without effective thermal management, battery performance and safety can be compromised.

Our mica insulation ensures:

• Thermal stability across every cell
• Passive fire protection, reducing the risk of thermal runaway
• Electrical insulation, protecting high-voltage components
• This combination ensures that battery packs remain safe even under the most demanding conditions.

Compression Pads Plus

Our Compression Pads Plus are designed to extend the life and safety of EV battery packs. By maintaining uniform mechanical pressure, they ensure secure electrical and thermal connections while allowing the battery pack to expand and contract during use.

The result? Longer battery life and enhanced reliability – critical for the performance of electric vehicles.

Sustainable Thermal Solutions

Sustainability is at the heart of modern automotive engineering. Our mica-based insulation and Elmtherm microporous materials help manufacturers design more energy-efficient, environmentally responsible vehicles.

Benefits include:

• Reduced energy loss through superior thermal regulation
• Support for net-zero initiatives, helping manufacturers meet environmental targets
• Lightweight insulation, which contributes to overall vehicle efficiency

Mica’s durable and lightweight nature makes it ideal for the diverse challenges of the automotive sector, from high-voltage battery packs to hybrid and alternative fuel systems.

Safety Above All Else in Aerospace

In aerospace, there’s no margin for error. Aircraft components operate under extreme temperatures, high voltages, mechanical vibration and weight constraints, requiring materials that provide the highest level of safety.

Mica-based insulation is uniquely suited to meet these requirements:

High-Temperature Insulation

Our mica insulation materials are used in:

• Aircraft interiors to provide thermal protection
• Heat shields to safeguard sensitive components
• Battery and avionics systems to ensure operational safety

Flight Recorder Protection

Flight recorders, or black boxes, are among the most critical components on any aircraft. They must survive catastrophic events, including fire, impact and even deep-sea pressure.

Mica’s non-combustible, heat-resistant properties protect these devices, ensuring vital flight data remains recoverable in any scenario.

Fireproofing and Thermal Shields

Mica-based composites also serve as fire barriers and thermal shields throughout aircraft systems. They prevent flame spread, contain heat, and protect critical electronics and components.

Industrial Insulation Expertise Beyond Mica

While mica is at the core of our business, our expertise extends to diverse insulation technologies:

• Flexible laminates for foundries and steel industries
• Rigid mica sheets and tubes
• Microporous materials with exceptional high-temperature insulation properties
• Gasketing and waterproofing applications

Our diversified offering allows us to respond flexibly to customer needs, whether delivering off-the-shelf solutions or highly bespoke products.

Why Choose Elmelin?

Choosing Elmelin means choosing a team that has a deep understanding of industrial insulation across multiple sectors, including automotive, aerospace, foundry & steel and more. Our long history means we’ve seen every kind of application, from high-voltage EV batteries to extreme aerospace conditions, and we know what works and what doesn’t.

Get in Touch

If you’re looking to improve safety or explore sustainable insulation solutions, get in touch with us today. Call us on 020 8520 2248 now.

Being a part of the responsible Mica initiative

Mica

Our heritage and our responsibility

At Elmelin, our history stretches back to 1912, when we began processing mica in Walthamstow, London. From these roots, we’ve grown into a specialist in industrial insulation, providing innovative high-temperature thermal and electrical solutions.

Serving industries as diverse as aerospace, foundry, automotive and domestic appliances, we’ve continuously evolved for more than a century.

Mica has always been at the heart of what we do. It’s a mineral with some remarkable properties: heat resistance, electrical insulation and versatility across countless applications. However, we also know mica’s story isn’t always a positive one. Too often, it comes from regions where poverty drives unsafe working conditions and, in some cases, child labour.

Because of our long history with mica, we feel a responsibility to be part of the solution.

Keep reading to learn more.

What is the Responsible Mica Initiative?

We’re proud to support the Responsible Mica Initiative (RMI) and commit to creating a supply chain that’s fair and sustainable.

The RMI is an international coalition of companies and organisations all committed to ensuring that mica is mined and processed in a way that respects people, communities, and the environment. Its work is focused on three pillars:

• Responsible Workplace Standards – promoting safe and fair working conditions.
• Community Empowerment Programs – creating alternatives through education, healthcare and livelihood opportunities.
• Legal and Governance Frameworks – strengthening regulations to protect workers and children in mica regions.

These efforts matter because mica is woven into modern life. It is used in paints, plastics, cosmetics and countless electrical and automotive components. The demand will only grow as industries innovate. If this demand is not matched by responsibility, vulnerable communities will continue to bear the cost.

By supporting the RMI, we are helping to transform the mica industry from the inside, building a supply chain that is fair and transparent.

Our Commitments for 2025

We’re not here just to talk about responsibility, we want to show how we’re putting it into action. For 2025, we set out some clear steps to support changes across the mica industry:

Taking a leadership role

We’re proud to be serving on the RMI board, helping shape the initiative’s overall direction. By being part of the decision-making, we can make sure the realities of industrial applications of mica are considered while pushing for stronger, fairer supply chains.

Full traceability through The Madagascar Project

Madagascar is a key source of phlogopite mica, the type we use most in our products. That’s why our involvement in the RMI Madagascar Project is so important. For the first time, it gives us traceability all the way back to the mine. This means we can be confident the mica we use is responsibly sourced, while helping ensure miners and their families are supported.

Supply chain transparency

We are integrating our mica supply chain into Tilkal, a blockchain-based platform that enables end-to-end traceability. This technology ensures that every step, from mine to finished product, is visible and verifiable.

Building on sustainability

Our involvement in RMI is an extension of our wider company vision: to enable net-zero carbon solutions through innovative insulation technologies. Just as we help customers reduce their environmental impact, we are committed to addressing social and ethical challenges in the mica industry.

As an ISO 9001:2015 accredited company, we apply rigorous standards of quality and continuous improvement not just to our products, but also to the way we source and manage raw materials.

Looking ahead

Mica miners and their communities depend on the global mica supply chain just as much as industries depend on mica’s unique properties. At Elmelin, we believe the path forward must be one where both thrive. Our work in 2025 and beyond will continue to focus on transparency and positive change.

To find out more about the Responsible Mica Initiative and how we’re making a difference, call us on 020 8520 2248 now.

Exploring the latest innovations in EV battery technology

Automotive

With the upsurge in electric vehicle demand over the past few years, the pressure for manufacturers in the automotive sector to stay ahead of the curve and develop solutions that are compatible with the latest EV technology and models becomes more apparent. There aren’t many other industries that have evolved so rapidly in recent time, and the EV market is showing no signs of slowing down.

Battery technology is at the heart of EV development, with research taking place all over the world to find alternatives and improvements for lithium-ion battery performance. As manufacturers of specialist insulation solutions for EV batteries, we appreciate first-hand how the sector works and have been able to collaborate with other experts to gain a full understanding of what’s required to stay competitive. We wanted to use this opportunity to look ahead at 2024, to explore the EV battery innovations worth keeping an eye out for.

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Looking after electric cars in Winter: Preparation & Safe Charging

Automotive

Winter is where festivities begin and we all look forward to a Christmas break seeing family and friends, however it can be a difficult time of year as well. Not only is the cold uncomfortable, but it’s expensive too. We spend more money on heating our homes, warm clothing and consumer electronics such as kettles and plug-in radiators.

Electric vehicles (EVs) have been revolutionary for the transportation sector, helping to reduce greenhouse emissions and our reliance on fossil fuels. They are however another example of victims to freezing temperatures. With an estimated 950,000 fully EVs on UK roads, many owners will want to keep them running optimally during winter months. As temperatures drop and the frost rolls in, it’s important to take extra care of EVs to ensure they remain reliable and safe to drive throughout the winter season.

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Digital Battery Passport: Overview, Benefits and Challenges

Battery Technology

With the surge in demand for electric vehicles and lithium-ion batteries, a pressing need to address the environmental footprint of such batteries across their entire lifecycle becomes increasingly important. This is why the digital battery passport was introduced, a concept poised to redefine the sustainability narrative in the battery industry.

The inception of the digital battery passport dates back to 2019, courtesy of the Global Battery Alliance (GBA). This collaborative initiative, uniting governments, companies, and non-governmental organisations, envisions a future where batteries contribute to sustainable and circular value chains globally. At its core, the digital battery passport represents a transparent framework, meticulously tracking a battery’s journey from its manufacturing origin to its eventual disposal. This holistic approach encapsulates vital information about a battery’s composition, origin, performance, and environmental impact.

In a bid to propel sustainable practices, the European Union (EU) emerged as a frontrunner in advocating for the integration of digital battery passports. Set to come into effect in 2027, the EU’s regulation mandates the use of these passports for all batteries sold within its borders. This regulatory stride not only underscores a commitment to transparency but also sets a precedent for the global battery industry.

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5 potential benefits of the planned UK battery gigafactory

Battery Technology

It was announced in July 2023 that Jaguar Land Rover’s (JLR) parent company, Tata Motors, will fund the development of a £4 billion EV battery gigafactory in the UK. Based in Somerset, the new gigafactory will be one of the biggest in Europe and have the capacity to manufacture a significant quantity of EV batteries for generations to come. Focussing on EV batteries for JRL vehicles first, the gigafactory will then open up its production capabilities to other automotive manufacturers, with production aimed to begin in 2026. The gigafactory will be the first of its kind outside of India and is thought to be a major step for the UK automotive sector and our journey to net zero.

The UK government has welcomed the investment, saying it will help to create jobs and boost the economy. It has also pledged to provide targeted support for the project. The hope is that through sustained, high volumes of production, the gigafactory will help to create a more sustainable and secure future for the UK transport sector as the number of EVs being purchased continues to rise. It’s thought that the UK is currently lagging behind some of its European rivals in terms of battery manufacturing capacity, so this investment from Tata Motors may prove to level the playing field.

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