Case Study: Multi-layer MEI system delivers enhanced heat retention for long turbo down tube applications

Challenge:

As emissions standards increased, engine manufacturers needed better ways to retain exhaust heat to support overall efficiency and regulatory performance. The customer asked for a solution that would reduce the temperature drop from the inlet to the outlet of a turbo down tube more than 1.9 meters long. Meeting this requirement meant maintaining high temperatures over an unusually long pipe, keeping every section fully insulated, and doing so without exceeding strict cost targets.

Solution:

Nelson Global’s engineering team developed a new multi-layer version of our metallic exhaust insulation (MEI) system. Traditional MEI uses a single fiberglass layer between 10.5 mm and 12.7 mm thick. The new design combined several different insulation layers, stacked in a way that achieved stronger thermal performance while keeping the overall thickness – and cost – within customer specifications.

Achieving the right thermal balance required extensive testing of various material combinations to determine the most effective layering sequence. Engineering, operations, and supply chain teams worked together to secure materials, build prototypes, and complete testing within the customer’s required timeline. The resulting design provided consistent insulation along the entire pipe length, preventing heat loss in areas that are typically harder to protect on longer exhaust systems.

Results:
The multi-layer MEI solution delivered meaningful improvements that aligned with the customer’s performance and efficiency goals:

• A 15% improvement in temperature-drop performance, equal to a measured gain of 3°C over competing designs.
• Reduced skin temperatures, improving safety and protecting surrounding components.
• Long-term durability, with strong resistance to vibration and thermal cycling.
• Better engine efficiency, contributing to improved fuel economy and fewer SCR regeneration cycles.

Impact:

This project demonstrates Nelson Global’s ability to enhance traditional insulation designs through material innovation and disciplined engineering. It showcases how our teams translate demanding thermal requirements into reliable, scalable solutions that perform consistently in real-world conditions. The multi-layer MEI design reinforces our expertise in solving complex heat-retention challenges – capabilities that apply across industries where efficient, dependable thermal management is critical.