May 26, 2025
Stephan-F. Reichinger is a civil engineer who studied at the University of Bochum. He is a certified TIPCHECK Expert (Level 3) and FROSIO Insulation Inspector (Level 3). His career began in 2006 at the ROCKWOOL Group, where he continues to provide technical support and consulting for clients. With over 20 years of experience in building physics, energy efficiency, insulation technology, software development, and fire protection, he brings extensive expertise to the Senergetics Advisory Board.
Stephan is recognized globally as an expert in evaluating and optimizing insulation systems, particularly with regard to the risk of corrosion under insulation (CUI). He is deeply committed to continuous learning, has contributed to several patents, and actively participates in various standards and technical committees focused on energy efficiency and heat loss calculation.
Since 2022, he has also been working part-time alongside his permanent role at ROCKWOOL Technical Insulation as an independent consultant through his own engineering and expert office, specializing in insulation systems for industrial facilities. At Senergetics, he contributes his strategic expertise to help solve complex technical challenges and drive innovation in sustainable industrial practices.
What excites me most about Senergetics’ mission and technology is the innovative approach of using wireless sensors that do not compromise the outer cladding of technical insulation systems. Especially in the field of industrial thermal insulation, preserving the integrity of the cladding is crucial to prevent long-term moisture ingress.
The combination of this sensor technology with AI-based data analysis opens up entirely new possibilities in the field of maintenance: potential moisture ingress can be detected early and precisely localized, without the need to open entire parts of the system based on assumptions. This not only saves time and costs, but also conserves resources by deploying maintenance teams only where there is a real need. In light of the increasing shortage of skilled workers in the technical sector, it is more important than ever to allocate available capacities in a targeted and efficient manner. Senergetics’ systems make a valuable contribution here by providing accurate indications of potential damage, based on precise measurement data and AI-supported analysis, exactly where action is required. This allows qualified personnel to be deployed more effectively, which is a decisive advantage in times of limited human resources.
In addition to enabling targeted maintenance, the technology also makes a significant contribution to energy efficiency and climate protection: heat losses caused by saturated insulation materials and the resulting CO₂ emissions can be effectively avoided. Furthermore, the risk of corrosion under insulation (CUI) is significantly reduced—a problem that, in practice, often leads to high costs and serious safety risks.
Over the next few years, I hope to work closely with Senergetics to further optimize its technologies and help implement them broadly across the industry, in order to provide sustainable and efficient solutions to the challenges of thermal and cold insulation.
I am firmly convinced that Senergetics’ system is not only a highly profitable investment, but also a sustainable one. From my professional experience, over 80% of plant operators are unaware of the weaknesses in their insulation systems. While many are familiar with the problem of corrosion under insulation (CUI), the most effective preventive measures, such as consistently applying rain-shedding cladding, are rarely implemented. In addition, there is often a lack of proper maintenance and a general unawareness of the far-reaching consequences, including heat losses, increasing CO₂ emissions, and the risk of severe corrosion damage.
It is important not to underestimate the impact of such corrosion: not only are there serious safety implications, but also considerable follow-up costs. Removing damaged insulation, labor-intensive rust removal, and reapplying corrosion protection coatings can lead to expenses in the five- to six-figure range. Moreover, the risk of sudden plant shutdowns due to undetected CUI damage can result in significant production losses and economic damage, posing a major threat to operational reliability and cost efficiency.
This is exactly where I see great potential in Senergetics' technology: the combination of wireless, non-destructive sensors, which are also suitable for use in explosion-proof (Ex) areas, and AI-driven data analysis makes moisture ingress visible and provides a solid foundation for proactive, condition-based maintenance. The visual representation of critical zones raises awareness among operators and decision-makers and enables targeted action before major damage occurs.
I hope that my support over the next two years will help reduce the current figure of over 80% of uninformed or poorly maintained systems. The more operators become aware of the vulnerabilities in their insulation, the more effectively energy losses, CO₂ emissions, and corrosion risks can be mitigated, making a substantial contribution to greater sustainability in industrial operations.
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