Erja Immonen & Antti Niemelä: Sustainability development in metal ceilings

Lautex Oy is a specialized manufacturer of suspended metal ceilings for the construction and shipbuilding industries. In addition to our core offerings, we also serve as a subcontractor for sheet metal industry. We provide ceiling panels, profiles, cassettes, and grating ceilings as comprehensive systems. These systems include suspension materials, air conditioning units, loudspeaker fixtures, and service hatches, all tailored to meet diverse customer requirements. Every product is proudly manufactured in Nummela, Finland.

In the shipbuilding industry, outfitting is often characterized by highly specific customer demands. To meet these needs, we supplement our standard products with custom-made solutions and decorative ceiling constructions, such as beams and domes. Lautex ceilings are not only aesthetically pleasing but also fire-resistant and lightweight, making them particularly well-suited for shipbuilding applications. They are easy to install and dismount, while also maintaining high hygiene standards.

Our primary materials—aluminum and steel—are selected with sustainability in mind. The aluminum we use is 80% recycled, and the steel is 20-25% recycled. This significantly reduces the consumption of virgin materials and lowers our carbon footprint. Importantly, both aluminum and steel are 100% recyclable, further enhancing the sustainability of our products. Our metal ceilings are designed for longevity, with a service life of up to 40 years, offering excellent resistance to wear and tear.

At Lautex, we are committed to reducing our environmental impact. All the electricity we use is CO2-free and certified. Given that we operate in a groundwater area, it is crucial that we do not release any emissions into the groundwater. The quality of groundwater is monitored regularly.

We also have our own powder coating line, which is a more environmentally friendly alternative to wet painting. Powder paints do not contain volatile organic solvents, thus avoiding VOC emissions that harm the environment. For pre-painted materials, our major supplier uses a system that captures more than 99% of VOC emissions.

A few years ago, we conducted a CO2 footprint analysis of our products and identified that the primary sources of CO2 emissions are our base materials: aluminum and steel. To reduce our carbon footprint, we have focused on optimizing product designs by reducing material usage, by optimizing support structures or switching to more sustainable materials. In some ceiling solutions, we have reduced weight by up to 30%, which directly decreases the product's carbon footprint. This approach not only enhances sustainability but also proves to be cost-efficient, unlike some other sustainability initiatives that tend to increase costs. Additionally, some of our products now feature completely new designs. One of our current challenges is the rapid pace of innovation—our technical designers are working diligently to translate new ideas into production-ready drawings. Our 3D design program is integral to both our product development and daily operations.

Lautex suspended ceilings are certified in fire resistance classes C, B-0, and B-15, meeting stringent regulatory requirements. Achieving fire resistance class B, for example, necessitates proper fire insulation, which we accomplish using mineral wool. Although there are promising innovations for lighter stone wool products, functional challenges remain before they can be fully integrated into our offerings. Lighter products, particularly in cruise ships, would significantly reduce emissions over the vessel's lifetime.

For fire resistance class B, steel is a required base material. We are particularly excited about the recent launch of fossil-free steel by our supplier, made from recycled steel using fossil-free energy. We eagerly await our first order of these coils to offer even more sustainable products to our customers.

Currently, we are conducting a full Life Cycle Assessment (LCA) for our main products. This assessment measures the environmental impact of a product throughout its lifecycle. Once completed, we will provide our customers with detailed data that they can use in their own calculations and development processes.

Since 2017, Lautex has been actively involved in sustainability projects, each lasting approximately two years. These projects are a collaboration between the University of Turku, companies in the maritime sector, and a Finnish research institute. Our goal is to be at the forefront of sustainability in our industry.