Inteco: Sustainable plastic components for an innovative climate ceiling

A new climate ceiling with a phase-change material

The new climate ceiling uses a salt mixture that can absorb heat and release it later. This material has a melting range between approximately 21 and 25 degrees Celsius, which falls precisely within the temperature range that feels comfortable in an office environment.

When the temperature in a room rises, the material absorbs heat. The salt mixture melts slowly as this happens, keeping the temperature more stable. At night, the material can solidify again with cool outside air, allowing it to absorb heat once more the next day.

This creates a largely passive system that is less dependent on mechanical systems, water circuits, and energy consumption.

Especially now that energy savings, CO₂ reduction, and grid congestion are becoming increasingly important, interest in these types of solutions is growing. For Inteco, it was therefore important that the components within this new system also align with that sustainable philosophy.

A plastic solution to a practical problem

For the climate ceiling, Inteco needed plastic components to secure and fix the packs within the system in the ceiling panel.

These consist of a bridge piece and a clip that together ensure the packs remain firmly in place. The components are not visible in the final product. As a result, color and appearance were less critical than they would be for a visible plastic product.

Since the climate ceiling is installed in large quantities, the solution also had to be simple and efficient to assemble. The components therefore had to not only function securely and reliably but also be practical to handle during installation.

The technical function, however, was indeed important. The bridge piece must be sufficiently rigid to hold the packs securely in place during use, transport, and installation. At the same time, the component had to be practical to install, fit within the ceiling structure, and continue to function reliably over the long term.

For Inteco, therefore, it was not just about a plastic component that works well today. The lifecycle of the entire system was also a factor. A metal ceiling panel can last for decades, while components behind the ceiling, such as HVAC elements, rubber seals, pipes, and connections, may require maintenance or replacement over time.

By designing components to be detachable and replaceable, a large part of the structure remains usable for a longer period of time. This aligns with Inteco’s approach to sustainability: focusing not only on the material itself, but also on the lifespan and maintainability of the entire system.

From 3D model to physically tested prototype

Inteco and Fleur Plastics first came into contact about two years ago, when Inteco was working on the launch of its new climate ceiling.

Inteco’s request was clear: develop a plastic solution that securely holds the packs in place, is sufficiently rigid, and fits within a sustainable and expandable ceiling concept.

Fleur Plastics collaborated on translating that request into concrete 3D models. These models examined the shape, the required rigidity, the connection to the ceiling panel, and the method for securing the packs.

The design process did not focus solely on the current product; future expansions were also factored into the design. Inteco wanted to account for a longer version of the climate ceiling. As a result, the solution had to be suitable not only for the existing size but also logically compatible with potential future products.

Based on the 3D models, Fleur Plastics had prototypes milled in China. Inteco was then able to test these physical models within the climate ceiling structure.

That was an important step. A 3D model shows what a product looks like, but only a physical prototype reveals how the component behaves in practice. Does it fit properly? Does the assembly make sense? Does the assembly stay securely in place? And does the bridge piece actually have sufficient rigidity?

Based on these physical tests, further adjustments were made to the design. For example, the component was refined step by step before investing in a final mold.

Material selection: Durable and sufficiently rigid

The choice of materials played a key role in this project. Inteco wanted to design the components to be durable, in keeping with the energy-efficient nature of the climate ceiling.

At the same time, the bridge piece had to be sufficiently rigid to reliably fulfill its function. For this reason, the team considered not only standard polypropylene but also talc-filled PP. Adding talc increases the material’s rigidity without compromising the fundamental advantage of a plastic solution.

The prototypes were manufactured with properties that matched those of the final material. This allowed Inteco not only to evaluate the shape and assembly but also to verify the component’s actual stiffness.

This prevented a situation where it would only become clear after the mold had been built that the material or design was not sufficiently suited to the application.

First, physical validation; then, investment in molds

Only after the 3D models had been converted into physical prototypes, the parts had been tested, and the necessary adjustments had been made was the next step taken: the construction of the molds.

This is a crucial moment in an injection molding project. A mold translates a product design into a production tool that enables plastic parts to be manufactured consistently and efficiently.

Because Fleur Plastics was involved as early as the development phase, the design, material selection, and production could be closely coordinated. Consideration was given not only to the part’s function but also to its manufacturability, stability, and reproducibility during the injection molding process.

For Inteco, this meant having a single partner for the entire process: from the 3D model and milled prototype to physical validation, mold construction, and final production.