PUF Panel Thickness Guide: 40mm to 150mm Explained

Choosing the correct thickness of PUF panels is one of the most important decisions when planning an insulated structure, such as a cold room, clean room, warehouse, or other heat-controlled facilities. The thickness directly affects insulation performance, temperature stability, energy consumption, suitability of the structure, and the cost of the installation.

PUF panels come in various widths, often between 40mm to 150mm. However, just because a panel is thicker does not mean that it is more effective for all applications. There are projects where one may require a 40mm panel while others may need a 100mm or 150mm panel for proper functionality.

The choice must be made based on a number of things including the working temperature, conditions inside and outside the premises, panel application, size of the room, operating hours, and level of thermal insulation required.

Through this guide, you will learn about the different thicknesses of PUF panels ranging from 40mm to 150mm and decide which thickness may be best fit for your needs.

What Is PUF Panel Thickness?

PUF panel thickness represents the thickness of the layer of polyurethane foam insulation placed between the outer sides of the panels. This foam insulation layer helps reduce the transfer of heat from the inside of a building to the outside.

In general, higher insulation thickness means a better insulator, but in actual practice, a panel's performance relies on many aspects, including the quality and density of polyurethane foam core, construction of the panel itself, joints, installation and conditions in which the panel is working.

Because of this, it can happen that a panel which is selected considering only the thickness is not an appropriate choice.

The common thickness options include:

• 40mm PUF panels
• 50mm PUF panels
• 60mm PUF panels
• 80mm PUF panels
• 100mm PUF panels
• 120mm PUF panels
• 150mm PUF panels

Each thickness has a different role depending on the application.

If you're specifying panels for a new build, our PUF Panels page covers full thickness options, core density, and specifications across our polyurethane foam panel range.

40mm PUF Panel: Where Is It Suitable?

The 40mm panel is one of the thin possibilities when it comes to PUF insulation. It may suit applications where there is moderate thermal insulation needed and the internal and external temperature is not too different.

These panels may be good for any common type of divider, the insulated area, commercial or some other applications when just moderate temperature control is required.

The major benefit of a 40mm panel is that it has a smaller material footprint and often needs less installation area than thicker panels do.

Nevertheless, a 40mm panel should not be chosen just because it is a thinner panel. If a project needs more effective temperature control, using a thin panel just to lower the initial cost may end up making operations harder down the line.

50mm and 60mm PUF Panels

When transitioning to the 50mm and 60mm thicknesses, insulation improves compared to the thinner panels, but the design itself is still relatively compact.

It is possible to select these thicknesses for applications where greater thermal separation is needed like in insulated walls, ceilings and partitions, as well as for some temperature-sensitive environments.

The specific appropriateness of insulation will vary according to the working conditions.

For instance, a room that simply has to be cooler than its immediate environment will have different insulation needs compared to a refrigerator room that must keep its environment freezing.

Thus, either a 50mm or a 60mm thickness should be chosen according to the actual thermal requirements and not just because it happens to fall in between.

PUF Panel 80mm: A Practical Insulation Option

When a project necessitates stronger insulation compared to the thinner panels, 80mm of thickness of PUF panel is one of the most frequently selected thicknesses.

The 80mm panel provides a thicker polyurethane insulation layer that helps minimize heat transfer and regulate temperature stability if appropriately designed and installed.

It may be considered for applications such as:

• Temperature-controlled rooms
• Insulated warehouses
• Food processing areas
• Industrial partitions
• Commercial refrigeration areas
• Selected cold-room applications

The advantage of switching to a thicker panel of 80mm is more than just the increased physical thickness. The considerable insulation can become even more useful, when the room must retain the required indoor climate for a long time.

Nevertheless, the thickness needed should be determined according to the project's temperature requirements and other design specifications.

PUF Panel 100mm: When Do You Need It?

The 100mm PUF panel is known to provide perfect thermal insulation, thereby being looked after in many situations where thermal management is of relevance.

For a project where there is a need to maintain the same temperature conditions inside while there are significant external temperature variations, a 100mm panel becomes applicable.

Potential applications include:

• Cold rooms
• Refrigerated storage areas
• Food storage facilities
• Temperature-controlled warehouses
• Industrial insulation systems
• Processing facilities

An important thing to note is that 100mm should not be considered a one-size-fits-all option. A project that needs 100mm insulation in one climate or temperature range may need a different specification in another circumstance.

The right way to go about this is first to determine what internal temperature is needed and then figure the insulation specification necessary to meet that temperature.

120mm PUF Panel: Higher Insulation Requirements

A 120mm PUF panel offers a higher thickness of insulation barrier which can be suitable for the usage in cases of high demands for protection against heat transfer.

Since the demands for insulation become higher, the thickness of panel materials matters more and more since temperature control is becoming more challenging.

A 120mm panel might be appropriate for specific cold-storage applications, huge temperature-controlled rooms, or areas that need thermal stabilisation.

On the other hand, additional thickness has to be taken into consideration in the beginning stages of the design. Dimensions of doors and rooms, as well as panel joints, supporting structures, and installation details, should be taken into account.

PUF Panel 150mm: Maximum Thickness in This Range

The 150mm PUF panel is at the thickest end of the thickness range mentioned here.

It is used in situations where superior insulation capabilities are essential, and limiting heat transfer is of utmost importance.

Possible applications include areas requiring cold storage, cold storage technologies, temperature-controlled environments, and other industrial processes that require good thermal insulation.

Using a thicker panel offers great insulation advantages. However, it comes with a greater amount of materials used and therefore might increase the cost of the project.

Therefore, by choosing 150mm only because it is the most thick option is not a wise choice. The goal should be to achieve the needed level of thermal performance without increasing the requirements unnecessarily.

PUF Panel Thickness Comparison

The following provides a simple way to understand how the different thicknesses can be positioned:

This table is intended as a starting point rather than a replacement for project-specific thermal calculations.

Does Thicker PUF Panel Always Mean Better Performance?

Not necessarily.

This is one of the most popular misconceptions when choosing insulated panels.

Typically, more thickness results in better insulation values. Nevertheless, performance of the complete assembly relies on more factors than just the thickness.

Important factors include:

1. Insulation Core Quality

The characteristics of a polyurethane core play a vital role in how well the panel can block heat transfer.

2. Panel Joints

Even a thick panel is useless if the joints are not designed or done right. Spaces between joints allow the air to flow and therefore transfer heat.

3. Installation Quality

Alignment, sealing, fastening, and finishing all need to be done right in order to get the effectiveness of the panel.

4. Doors and Openings

Repeatedly opened doors may add a considerable amount of heat to an unheated space. Increasing the thickness of the walls alone cannot solve the issue of poor access control or inappropriate door design.

5. Ceiling Insulation

Heat can enter through the roof, which means that insulation of the ceilings is equally important as insulation of the walls in many situations.

This is where the PUF ceiling panel becomes important. The panel must be chosen based on the same thermal requirements as those used to select other thermal sections.

How to Choose the Right PUF Panel Thickness

Before selecting a panel, consider the following factors.

Required Internal Temperature

The first question should be: what temperature does the facility need to maintain?

To illustrate, a general insulated room and a low-temperature storage facility have different kinds of requirements.

External Temperature

The climatic conditions of the surrounding area also play an important role. A facility exposed to extensive outdoor temperature changes may need more insulation than a facility existing in a more controlled environment.

Type of Application

Determine whether the panel is being used for:

• Walls
• Ceilings
• Cold rooms
• Freezer rooms
• Warehouses
• Food processing areas
• Industrial partitions
• Clean environments

Different applications can have different requirements.

Energy Efficiency

Proper insulation at a facility may help to lower the heat load that refrigerating and other temperature-controlling systems need to deal with. Hence, the insulation thickness may play an important role in long-term operating cost analysis.

Budget

The cost of installing the panels is important, but it is not the primary concern. Using a very thin panel may save costs, but it may end up increasing the need for cooling and heating for the owners of the building.

Thus, the aim should be to find the appropriate thickness needed to provide the required performance.

PUF Panel Thickness and Energy Efficiency

Insulation is crucial in regulating heat transfer through walls and ceilings. An insulation system that is designed correctly can result in maintaining the desired conditions indoors while minimizing the unwanted heat gain. The importance is important for refrigerated and temperature-regulated buildings because the refrigeration system might otherwise require more energy to keep the temperature at the desired level.

Nevertheless, the thickness of the panels alone does not determine energy efficiency.

An effective insulated system is made up of many components including the panel joints, doors, floors, ceilings, cooling equipment and air infiltration, as well as the purpose of the room and the operational conditions.

In other words, a poorly installed 150mm panel does not necessarily make better performance compared to a correctly designed and installed 100mm panel.

80mm vs 100mm PUF Panel: Which Is Better?

The answer depends on the application.

A PUF panel of 80mm might be adequate in situations where the degree of thermal control is moderate. When greater insulation performance is needed, a PUF panel of 100mm may be more suitable.

Rather than asking which thickness is universally better, ask:

What temperature must the room maintain, and what level of heat transfer can the system tolerate?

If the answer suggests that it is necessary to have an additional insulation barrier, then it could be worth considering a thicker wall panel. If use does not require the additional insulation, on the contrary, it is reasonable to choose a very thick panel, but it may result in unwanted expenses without the possibility to gain any useful effect.

Final Thoughts

Picking the right thickness of a PUF panel is not just about choosing the thickest one. Different thicknesses from 40mm to 150mm are meant for different purposes. In fact, while thinner panels can be presumably used for thermal insulation and partition purposes, thicker ones like 80mm, 100mm, 120mm, and 150mm could be used in more demanding temperature-controlled processes.

In determining which cold room and refrigeration panel to use, a number of factors and conditions should be taken into consideration, among them the temperatures inside and outside the room, the design of the room and its insulation, the load on the refrigeration system, and the method of installation.

Thus, the best panel may not be the one of the greatest thickness; it is the thickness of the panel which achieves the desired thermal performance while making sense financially and technically.

Check the entire insulating system before determining your PUF panel specifications. Be sure to include the walls, ceilings, joints, doors, and other sources of heat transfer in your evaluation, so that the thickness is sufficient for the needs of the facility.

Frequently Asked Questions About PUF Panel Thickness

1. What is the ideal PUF panel thickness for a cold room?

There is no uniform thickness for each cold room. The thickness of the PUF panels required will depend on the temperature of the cold room, the surroundings, the size of the room and its purpose and working requirements, and the thermal performance expected. In cases of heavy insulation requirements, thick panels, such as 80mm, 100mm, 120mm, or 150mm, can be used.

2. Is 100mm PUF panel suitable for cold storage?

A 100mm PUF panel can be used for various cold storage purposes where higher insulation is required, yet the optimal thickness must not only be established based on the thickness, but on the temperature required for storage as well as the complete design of the room.

3. What is the difference between 80mm and 100mm PUF panels?

The main factor should be taken into account while differentiating between PUF 80mm and PUF 100mm is the thickness of their polyurethane insulation core. PUF panels of 80mm are less effective in insulating than PUF panels with 100mm thickness. However, the choice of the more beneficial variant depends on the thermal needs of the customers.

4. Is a thicker PUF panel always better?

No. A thicker PUF panel will provide more insulation, but that does not make it the best option. If a panel is too thick for the purpose of the project, the required thickness will lead to higher costs without any benefit.

5. What PUF panel thickness is used for ceilings?

The thickness necessary for a PUF ceiling board must be determined by the kind of thermal insulation needed for the structure or site. Ceiling applications should be analyzed with regards to wall insulation, since heat may also be conducted through the roof or ceiling. The final specification should take into account the working temperature and environmental conditions.

6. What are the common PUF panel thicknesses?

PUF panel thickness comes in standard sizes of 40mm, 50mm, 60mm, 80mm, 100mm, 120mm, and 150mm. The choice is based on the application of the PUF panel, insulation needed, and temperature conditions.

7. How does PUF panel thickness affect energy efficiency?

Larger insulation thickness is more effective in minimizing heat loss through the PUF panel; therefore, the required internal temperature can be maintained and heat load on temperature control and refrigeration machines minimized. However, overall efficiency depends on installation quality, joints, doors, ceilings, floors, and appliances.

8. Can 40mm PUF panels be used for cold rooms?

While a 40mm panel might work for specific insulated needs, it cannot be taken for granted that it will work in every cold room. Low-temperature purposes commonly need a better evaluation of the insulation efficiency that must be provided before the thickness of the panel can be determined.

9. How do I choose between 100mm, 120mm, and 150mm PUF panels?

The selection needs to be made on the basis of the desired internal temperature, the conditions of the exterior, design of the facility, energy needs, and budget of the project. In such a case where a thick panel is needed to provide higher thermal insulation, the final choice should be taken based on the global system, not on the panel thickness solely.

10. Does PUF panel thickness affect the cost?

Certainly. Raising the thickness of the panel usually means that more insulation is utilized, which can lead to a rise in initial costs of the panel. Nevertheless, the least expensive panel is not always the most cost-effective option throughout the life of the building. This means that it is important to find the optimal thickness that strikes the right balance between the initial investment and the necessary thermal performance and other operating requirements of the building.

Singhania Refrigeration manufactures and supplies PUF insulated panels across the full thickness range — from 40mm to 150mm — for cold rooms, warehouses, and industrial facilities across Delhi NCR, and can help you specify the right panel thickness for your project. Explore our PUF Panels range, or get in touch to discuss your requirements.