Life Cycle Analysis of Mr. Insulate Cotton Armor Insulation Just Released by Applegate Insulation

Share Article

A new Life Cycle Analysis shows that Mr. Insulate Cotton Armor insulation trumps traditional fiberglass insulation in embodied energy and ecological impact

Mr. Insulate Cotton Armor installation.

Cotton Armor is an environmentally sustainable insulation.

By making use of natural fibers as opposed to overly manufactured man-made materials, Cotton Armor is the demonstrated choice for a sustainable and environmentally friendly insulation.

In a recent Life Cycle Analysis (LCA) conducted on Mr. Insulate Cotton Armor Acoustical and Thermal blanket insulation, Applegate Insulation found significant reductions in energy use, greenhouse gas emissions and even the amount of water used to produce Cotton Armor, compared to traditional fiberglass manufacturing. The LCA highlights the environmental benefits of reusing American resources to further save American energy and the environment. It should be noted that proper installation is easier with Cotton Armor than competitive products and thus Cotton Armor can provide more energy savings over the life of a building. The LCA did not take this into account, had it done so the environmental advantages of Cotton Armor would have been even greater.

The objective of the Life Cycle Analysis was, " determine and compare the Greenhouse Gas (GHG) emissions, water and energy required to produce $1 million of output of fiberglass insulation produced by the mineral wool industry with insulation produced from yarn spun from recycled waste cotton."

The findings of the LCA were fairly surprising and are critical for knowledgeable green building, with Cotton Armor demonstrating, "...a 54 percent reduction (of CO2 equivalent gasses) compared to the emissions of insulation made from 100 percent fiberglass. The most significant savings come from two areas. First, the use of 100 percent recycled denim as a raw material compared to the mining of silicate and other mineral raw materials for traditional fiberglass. The second, and largest, impact is from the use of electricity and fossil fuels (mainly natural gas) needed to fire furnaces needed to turn silicate to glass."

Cotton Armor insulation used 54% less energy to produce mainly because, "The production of recycled denim fiber cotton insulation also is significantly less energy intensive than conventional fiberglass insulation since it has no need for furnaces to melt silica and glass," and, "The production of recycled denim fiber cotton insulation results in significantly less water use than conventional fiberglass insulation, a 29 percent reduction." Thus, by making use of natural fibers as opposed to overly manufactured man-made materials, Cotton Armor is the demonstrated choice for a sustainable and environmentally friendly insulation - saving both raw materials and energy through the use of recycled cotton.

Applegate launched Cotton Armor Acoustical and Thermal blanket insulation in order to rectify many issues of yesteryears batt technology. Cotton Armor's proprietary production process gives it a unique fiber layout, making it easy to tear by hand or cut with a utility knife. Cotton Armor’s friction fit and correct sizing for residential and commercial framing helps make poor installations a thing of the past. Cotton Armor qualifies for up to 11 LEED credits, has STC ratings into the 60’s, R-values of up to 3.9 per inch and with its ease of sizing and installation Cotton Armor is among the highest performing sustainable insulations available to builders, specifiers and designers today. Besides building insulation, Cotton Armor is available as acoustical panels along with duct and pipe wrap insulations.

Established in 1978, Aaron and his son Terry Applegate began manufacturing cellulose insulation out of a small facility in Okemos, Michigan. Today, Applegate headquartered in Webberville Michigan, is the largest privately owned cellulose insulation manufacturer in the world, and supplies a variety of high performance insulation products throughout the United States. Applegate currently operates facilities in Michigan, Wisconsin, Pennsylvania, Kentucky, Georgia, Louisiana, and Colorado. For additional information regarding Applegate Insulation please visit To learn more about Cotton Armor insulation or to request a copy of the LCA please visit, or call (855) 6-COTTON.


For editorial interviews, additional information, testimonials, photographs, and industry specs please contact: Aaron Applegate, 800-627-7536 ext 311 or e-mail

Share article on social media or email:

View article via:

Pdf Print

Contact Author

Aaron Applegate
Visit website