ARMO Showcase 2023

Showcase. Rotational Moulding Product

Lowest Cost of Ownership

Highest Productivity, Durability

Remote Ethernet Machine Suppor t

Automated Systems & Solutions

Global Sales & Full-Service Suppor t Team

Over 1,400 Machines in Over 60 Countries

Carousel Mold Swing Areas to 239” (6m) & Arm

Showcasing the Advantages of Rotational Moulding

It is with great pleasure that we introduce the latest “Special Edition” of the ARMO Rotational Moulding Showcase publication, which focuses on showcasing innovative products in the rotational moulding industry.

This issue is dedicated to showcasing the many advantages of rotational moulding, as well as exploring future trends and promoting information sharing within the industry.

Rotational moulding is a versatile manufacturing process that has been used for decades to produce a wide range of products, from large tanks and containers to small toys and household items.

In recent years the global industry has continued to push the boundaries to further prove the capabilities of Rotational Moulding. While there has been great development within the area of specialised materials and improved technology there still seems to be an opportunity for growth and development in this area.

Looking to the future, we see exciting trends emerging in the rotational moulding industry, including the use of new materials and technologies, as well as a growing focus on sustainability and environmental responsibility.

ARMO is represented by 12 associations from all over the globe and prides itself in what has been achieved over the years.

As ARMO, we are committed to promoting information sharing and collaboration within the rotational moulding industry. We believe that by working together, we can continue to drive innovation and growth in this dynamic and important sector.

We hope that you find this publication informative and engaging, and we look forward to your feedback and contributions as we continue to explore the many opportunities and challenges facing the rotational moulding industry.

Sincerely,

Wayne Wiid ARMO Chairman wayne@pioneerplastics.co.za

Looking to the future, we see exciting trends emerging in the rotational moulding industry, including the use of new materials and technologies, as well as a growing focus on sustainability and environmental responsibility.

ARMO Rotational Moulding Showcase is an annual marketing publication by the Affiliation of Rotational Moulding Organizations (ARMO) and published by JSJ Productions, Inc.

ARMO Board of Directors

Past Chair & IT-RO Representative – Katia Zoppetti, DRAM S.r.l. katia.zoppetti@dramsrl.com

‘Rotopol’ Representative – Dr. Marek Szostak, Poznan University of Technology marek.szostak@put.poznan.pl

ARMSA Representative – Wayne Wiid, Pioneer Plastics wayne@pioneerplastics.co.za

Past Chairman & BPF Representative – Martin Spencer, Unique Roto Martin@UniqueRoto.com

ARM Representative – David Smith, H. Muehlstein DLSmith@Muehlstein.com

AFR Representative – Francois Kieffer francois.kieffer@bwt.fr

Anipac Representative – Eduardo Guizar, Spincraft eguizar@spincraft.onmicrosoft.com

ARMA Representative – Scott Magill, Plastic Tanks QLD scott@ptq.com.au

Past Chairman & ARM-CE Representative – Oliver Wandres, MAUS ow@maus-gmbh.de

Nordic ARM Representative – Ronny Ervik, Norner ronny.ervik@norner.no

RPC – CPPIA Representative – Jacky Wang, Zhejiang Rotoun Plastic Technology Co., Ltd. jacky@rotoun.cn

Past Chairman & StAR Representative – Ravi Mehra, International Consulting - Maramehra LLC maramehra@aol.com

Publisher

Publisher – JSJ Productions, Inc.

Chief Editor – Susan Gibson JSJ Productions, Inc. susan@jsjproductionsinc.com

Editor & Marketing Director – Jennifer Gibson JSJ Productions, Inc. jennifer@jsjproductionsinc.com

Designer – Anya Wilcox JSJ Productions, Inc. awilcox@designintersection.com

Internet & Digital – Jason Cooper JSJ Productions, Inc. jason@jsjproductionsinc.com

Distribution – Sheryl Bjorn JSJ Productions, Inc. sheryl@jsjproductionsinc.com

Legal – Joseph V. Gibson, IV JSJ Productions, Inc. jvg@jsjproductionsinc.com

Editorial Contributors

Alvin Spence, Centro Incorporated ASpence@centroinc.com

Susan Gibson, JSJ Productions, Inc. susan@jsjproductionsinc.com

Product Showcase / Photo Contributors

Remote Operated Water Rescue Craft - India

The Flex Box - South Africa

Foot Pedal Wheelie Bin - India

Tenjam Shayz™ In-Pool Lounger - USA

Recycled Bead Tank - Australia

Chubby - Italy

Ferrari Jumps & Trifectas - Australia

Uncle Dan’s USA T-Post Feeder - USA

Inquiries

info@armo-global.org / armo-global.org / rotoworld@rotoworld.com

Reproduction

All Copyrights belong to ARMO and in no part may this publication be reproduced or transferred through any digital or electronic means, photocopied, or otherwise without the written consent of ARMO and the Publisher, JSJ Productions, Inc.

ANIPAC THE MEXICAN PLASTIC ASSOCIATION

www.anipac.com

Herschel # 188, Col Anzures

Mexico, D.F.

Miguel Hidalgo, 11590

Eduardo Guizar

(55) 62 73 88 44 • +27 865682675

ARM - ASSOCIATION OF ROTATIONAL MOLDERS

www.rotomolding.org

North America

USA

3400 W Stonegate Blvd, Suite 2315 Arlington Heights, IL 60005 +1 630-942-6589

Adam Webb adamw@rotomolding.org

AFR - ASSOCIATION FRANCOPHONE DU ROTOMOULAGE

www.rotomoulage.org

French-language countries

France

Immeuble Danica B 21 Avenue Georges Pompidou, 69003 LYON, France +33 67 0452 117

Francois Kieffer, Chairman

Anne De Lansalut, Permanent Member of the Board a.delansalut@rotomoulage.org

ARMSA - ASSOCIATION OF ROTATIONAL MOULDERS SOUTHERN AFRICA

www.armsa.co.za

Southern Africa

Johannesburg South Africa

P.O. Box 8184, Centurion, 0046, South Africa

+27 72 245 5310

Gary Wiid - Chairman info@armsa.co.za

SOCIETY OF ASIAN ROTOMOULDERS (STAR) www.starasia.org

India and Asia

“ROTOPOL” ASSOCIATION

www.rotopol.put.poznan.pl

Poland

60-965 Poznan, Piotrowo 3 street +48-61-6652776 • +48-601785126

+48-61-6652202

Dr. Marek Szostak, President of, ROTOPOL, Association marek.szostak@put.poznan.pl

NORDIC ASSOCIATION OF ROTATIONAL MOULDERS (NORDIC ARM)

www.nordicarm.org

Scandinavia

Iceland

Gunnarsbraut 12, 620 Dalvk, Iceland

+354 863-5373

Ronny Ervik ronny.ervik@norner.no

IT-RO ITALIA ROTAZIONALE www.it-ro.it/it

Italy

E. Brigatti, 12 - 20152 - Milano (MI) +39 348 7652 560

Katia Zoppetti, President info@it-ro.it

3rd Floor, 36 Krishna Market, Kalkaji, New Delhi- 110019, India

+91 9810305356 • +91 11 41634952

Ravi Mehra, Founding Chairman StAR S.B.Zaman, Executive Director StAR sb.zaman@starasia.org

RPC-CPPIA

www.chinarotomoulding.com/

Greater China Region including Mainland China, Taiwan, Hong Kong and Macau

RPC-CPPIA

Room 202, Lon 72, No. 1501, Tong Pu Road, Pu Tou District, Shanghai, China 200333

86 21 6237 1991 • 5271 5002

86 21 6237 1991 • 5271 5002-8005

Mr. C.C Shi, Secretary-General, Jacky Wang, Foreign Affairs Officer – for foreign affairs (English communication) jacky@rotoun.cn

BPF ROTATIONAL MOULDERS GROUP

www.bpf.co.uk

United Kingdom

6 Bath Place, Rivington Street

London EC2A 3JE

+0044 (0)207 457 5013 • +44 20 7457 5045

Graeme Craig, BPF Rotational Moulding Group Executive gcraig@bpf.co.uk

ARM-CE -ASSOCIATION OF ROTATIONAL MOULDERS CENTRAL EUROPE

www.rotational-moulding.de

Central Europe Germany

Keltergrasse 6, D-76356 Weingarten +49 721 948 7412 • +49 721 948 7444 Oliver Wandres info@rotational-moulding.de

ARMA - ASSOCIATION OF ROTATIONAL MOULDERS AUSTRALASIA LTD

www.rotationalmoulding.com

Australasia

Australia

PO Box 237 Moonee Ponds VIC 3039 Australia

+61 (0)404 265 887 • +1 630 790 3095

Michelle Rose

michellerose@rotationalmoulding.com

This product can be operated from up to 1 km Line of Sight and Radio Communication up to 2 kms. This can be deployed from a helicopter, ship from a height of 10 meters near a drowning person and steered using a remote.

Remote Operated Water Rescue Craft

A drowning person can hold on to the antiskid handles and can be pulled to shore / boat / jetty.

Designed for Saif Marines Pvt Ltd. by Satish Gokhale and team Design

Directions Pvt. Ltd. and manufactured by Vinodrai Engineers – India

Drowning is the 2nd largest cause of deaths, and to save a person struck in this panic situation the golden time is only 3 minutes. There are cases when there are no lifeguards on the beaches or it is difficult to reach the person in distress using conventional lifebuoys.

Patented Remote Operated Water Rescue Craft, is a battery powered and jet propelled lifebuoy which is compact and fast (ability to travel at 7 m/sec on

water OR 14 Knots) and can be easily manoeuvred to reach the person in distress. A drowning person can hold on to the antiskid handles and can be pulled to shore / boat / jetty. In case it is observed that the person to be rescued is unconscious, a person is sent along with the craft to help the drowning person since the craft can pull up to 3 persons.

This craft is better in many ways than

its global competitors. The main pluses over the competition is the high speed, stability in choppy conditions, and its self-righting capability and good visibility of the craft in choppy sea conditions.

The Rotational Moulding process was used for a much better quality control and uniform hull. The product is manufactured utilising 100% UV stabilized, recyclable HDPE material, which is best suited for all types of waters.

Being a product deployed on water, water tightness is an integral part of the design, and very important to protect all the electronic and electrical components. This was specially taken care of in each and every stages of the design. End goal was to make it easy to manufacture in bulk using the CNC machined moulds and cooling fixtures to avoid and reduce unwanted distortions of the moulded parts.

The overall size considerations were based on how the craft was going to be thrown in the water. It had to be as compact as possible and as light as possible.

This product can be operated from up to 1 km Line of Sight and Radio Communication up to 2 kms. This can be deployed from a helicopter, ship from a height of 10 meters near a drowning person and steered using a remote. In case the craft turns turtle when deployed in choppy sea conditions, it self-rights or straightens itself by buoyant self-righting structure, which doubles as visibility block to spot the craft in sea - a unique feature amongst all global competition.

The designers are working on add-ons to transport, food, medicines, clothes, etc. during flood situations. 180 units have been successfully inducted in the Indian Navy.

The Flexbox

A home gym station designed to be a personal home gym that looks like a modern piece of furniture when not in use.

Designed by Nick Swardt and manufactured by Pioneer Plastics – South Africa

The Flexbox is a Home Gym Station designed to be a personal home gym that looks like a modern piece of furniture when not in use. The product is manufactured by Pioneer Plastics with our client seeing the need for a functional, yet aesthetically pleasing, home gym station.

The box is designed as a home gym system with one of the main features being that the user can store his or her weights inside, while the lid acts as an incline bench to exercise the different muscle groups.

Due to its smart design, the home gym system doubles as an item of furniture which, when shut, will happily fit seamlessly into the average living room, but when the resident or guests wish to work out, all manner or gym exercises can be performed and in flash too.

The product consists of thirty-three individual parts, of which 5 are rotational moulded and polyurethane foamed for stiffness. The moulds are CNC machined moulds designed and manufactured in-house at Pioneer Plastics. The design intent was to develop a high-quality product aimed at fitness enthusiasts that is aesthetically appealing when not in use. The Flexbox also has numerous moulded inserts, and the design allows for an inserted Bluetooth speaker.

The product was designed together with a South African entrepreneur, now resident in the USA, coming up with the concept. Nick Swardt, Technical Manager at Pioneer Plastics, designed and developed the final product.

This is a brand new product launching this year with the first orders received to be supplied to the South African market as well as exported soon.

The user can store his or her weights inside, while the lid acts as an incline bench to exercise the different muscle groups.

Foot Pedal Wheelie Bin

Introducing an Innovation in Waste Management

Designed by Satish Gokhale and team Design Directions Pvt Ltd. and manufactured by Frontier Polymers Pvt Ltd. – India

In an era of increasing environmental awareness and sustainable practices, waste management solutions have become an integral part of every establishment’s operations. Catering to the needs of hotels, restaurants, airports, and similar high-traffic venues, we proudly present the revolutionary Foot Pedal Wheelie Bin – a game-changer in waste disposal efficiency and hygiene.

Key Features and Benefits

Hands-Free Operation: The hallmark of our Foot Pedal Wheelie Bin is its hands-

free design, allowing users to dispose of waste without the need for direct contact to the lid. In high-traffic areas like hotels, restaurants, and airports, where hygiene is paramount, this feature drastically reduces the risk of crosscontamination and the spread of germs. The strategically positioned foot pedal ensures that waste disposal is effortless and convenient. Users can easily open the bin’s lid using their foot, making it suitable for people of all ages and physical abilities. Full closure lid coupled with its sturdy built quality, helps contain

Crafted from highquality, eco-friendly materials, our wheelie bin is designed to withstand the rigors of heavy daily usage.

odours effectively. This is especially crucial in hospitality settings where guest satisfaction is paramount.

Durability and Longevity

Crafted from high-quality, eco-friendly materials, the wheelie bin is designed to withstand the rigors of heavy daily usage. Its robust construction ensures longevity, minimizing the need for frequent replacements and reducing the overall environmental impact. Made from Hexene polymer and UV stabilised, non-fading colours, and utilising cast aluminium tooling, these bins can withstand harsh outdoor weather conditions for years to come.

Customizable Design

We understand that different establishments have unique aesthetic preferences. Frontier Wheelie Bins are available in a range of three sizes of 70, 90, and 120 Liters. For waste separation, different colour lid options are available. Colour coded wheel caps adds to the overall aesthetic design appeal allowing seamless integration into your venue’s existing decor.

Tenjam Shayz™ In-Pool Lounger

The most comfortable pool lounger in the world. Designed by Tenjam and manufactured by Tri-Ven – USA

Tenjam furniture created Shayz - the most comfortable in-pool lounger in world. Featuring a patent pending Speed Fill Ballast System and three heights of snap-in risers for various pool depths up to 17”. Armrests were added for easier entry and exit from the seat and a “social” backrest angle is a more comfortable position for talking, watching, reading, and sipping a refreshment. Designed to comfortably fit the entire family from children to adults. Tenjam’s focus on comfortable and easy to use rotomolded furniture is creating a splash in the pool market.

Rotomolding is used to optimize durability, functionality, comfort, aesthetic appeal, design-for manufacture, and integration of differentiating features:

• Cupholders.

• “Speed-Fill” ballast system.

• Speed emptying system.

• Flow-through seats.

• Seat drain.

• Integrated handles.

• Stackability.

Shayz™ is offered in 14 colors with high UV stability to ensure color vibrance in outdoor environments. It has optional risers (three optional heights: 9”, 13” & 17”) that snap into the bottom of the Shayz™ lounger to accommodate various water depths.

Tenjam’s focus on comfortable and easy to use rotomolded furniture is creating a splash in the pool market.

Recycled Bead Tank

Be Green, Read from the Screen

Designed and manufactured by Suncoast Waste Water Management – Australia

Rotomoulding is a sintering process traditionally done with micronised PE but, not essential as it is possible to sinter bead in the same process.

Suncoast Waste Water Management manufactures a multi-layered LLDPE tank incorporating three layers. The outer layer consists of a melt compounded virgin micronised powder. The middle layer consists of a recycled PE in a Bead form, this polymer is NataLab Batch tested to check conformity to our AS/NZS Standard. The inner layer consists of micronised PE to produce a smooth inner layer giving the tank the required impact resistance. Tanks are produced using a templogger for correct multilayer points and piat.

OzziKleen products can recycle water and waste water in a recycled tank. 75% of material in a tank can be recycled LLDPE.

Ozzi Kleen Sewerage Systems act as a digestive system using a unique cyclic

fully aerobic sewage treatment process. This means there is no septic process, so no septic smells, it’s environmentally friendly producing nutrient rich water to reuse on gardens and is cost efficient to run (only half the running cost of other aerobic sewerage systems).

The heavy-duty polyethylene Ozzi Kleen sewerage system tank is up to 20mm thick and is, weight for weight, 100 times stronger than concrete. The material has a 500-year half-life. As the Ozzi Kleen RP10 sewage treatment system tank is roto-moulded and completely seamless, there is no risk of seepage, leaking, or root intrusion.

The Ozzi Kleen RP10 sewerage system tank is not affected by the acidity of sewage. Polyethylene materials are often used to store hazardous chemicals. The mechanical components are all designed and constructed to ensure years of effect, trouble-free service, and are backed with a full manufacturer’s warranty.

OzziKleen products can recycle water and waste water in a recycled tank. 75% of material in a tank can be recycled LLDPE.

Chubby

Chubby is a perfect mix between the beauty of the lines and the comfort of the seat.

Designed Marcel Wanders for SLIDE Srl – Italy

The armchair Chubby, created by the famous designer Marcel Wanders, is one of the best products of the whole Slide production. Chubby is a reinterpretation of Crochet Chair: it has got the same design but, it is made in polyethylene, suitable for every kind of people. The design armchair Chubby is suitable with every kind of settings, for contract, events, or private houses.

Thanks to its sinuous and linear design, Chubby is a perfect mix between the beauty of the lines and the comfort of the seat.

The Chubby Collection includes the Chubby, Chubby Low, and Chubby Side

Table. It began production in 2008. Its dimensions are 130 x 120h 56 cm (seat H 27 cm). Its packaging dimensions are 131 x 121 x 57 cm and packaging volume 0,903 m3. It comes in thirteen standard colors and 8 lacquered (glossy/matt) finishes. Its weight is 25 Kg.

The product is made from Polyethylene with the rotational moulding process. It is resistant to extreme temperatures (-600°C to +800°C). It is UV resistant and has high tensile strength. SLIDE® has a closed production cycle with no health prejudicial emissions and complies with ecological sustainability rules.

slidedesign.it

The design armchair Chubby is suitable with every kind of settings, for contract, events, or private houses. Thanks to its sinuous and linear design, Chubby is a perfect mix between the beauty of the lines and the comfort of the seat.

Ferrari Jumps & Trifectas

The Ultimate’s: Jumpstarts and Trifectas

Designed and manufactured by NexGenRoto in conjunction with Massey Designs – Australia

NextGenRoto Jumpstarts are solid and versatile. They can be used at several different heights, are safe for the horse and rider, and have no sharp edges. The product is UV stabilised and made super strong. It can be filled with water for extra stability, is easy to stack or leave on the arena, takes standard wooden poles, and comes in a range of colors.

The Jump is a definite money saver because you can make multiple jumps with one set of jump wings. It is a complete all-rounder as it will do it all: Cavaletti’s, Single Jump Spreads, Boxers, and Oxers.

The Ultimate Jump has 9 different heights, ranging from 11cm to 110cm, and the best part is you don’t need cups (no more losing jump cups). The jumping heights are imprinted into the jump for easy setup. It is very stable at 8kgs each side, which makes it easy to move around but can be pegged down or filled with water for stability.

The NextGenRoto Trifecta is a saddle rack, grooming/tack tray, and mounting block. It is the most versatile product on the market. The saddle rack fits easily into the back seat, car boot, or float. The saddle will fit perfectly on top, and the shape is protected and cannot be compromised. The Grooming Tray is designed for packing tack into the grooming tray provide and slide tray in the caddy storage area. The Mounting Block is purpose designed to mount a horse. It reduces strain on the horse’s back and helps maintain the rider’s

balance. It stops stirrup leather being stretched, is used for a seat, and is perfect for quick saddle changes. It has hands on both ends and 2 anti-slip steps. Very stable and sturdy, the Trifectas are light weight, UV stabilized, and have no sharp edges. Their weight is 6kg, 45cm high x 43cm wide x 54cm long. The weight rate is 130Kg.

At NextGenRoto, we’re not just about water tanks. Our talent and expertise in rotational moulding means that if you’re looking to develop a customised product, we have the experience and commitment to get the job done to the highest of standards.

We take pride in our work, and we ensure that the concept you need manufactured is delivered on time, and of the highest quality. From the materials we use, to the experts who lead our custom design projects, we make certain that what we produce is right every time. Our quality control method is of the strictest standards, we don’t cut corners, they are industry-leading quality control procedures. An idea is all you need to get started. Our development process is simple and straightforward.

nextgenroto.com.au

The Jump is a definite money saver because you can make multiple jumps with one set of jump wings. It is a complete allrounder as it will do it all: Cavaletti’s, Single Jump Spreads, Boxers, and Oxers.

Uncle Dan’s USA T-Post Feeder

Great Products for Great Hunters

Designed by Dan Ross and manufactured by Ken Ross Rotational Molding – USA

The Uncle Dan’s T-Post wild game feeder was designed using an ordinary T-Post to secure the feeder outdoors. Using customer-supplied T-Posts keeps the retail price lower than competitors who rely on leg kits produced in China and supplied with their feeders. Using a T-Post driven into the ground provides an exceptionally secure system that is resilient against game or livestock destruction. The four individual feed ports are equipped with slide gate valves to regulate the flow of different types of feeds - corn, protein pellets, finely ground attractants, and feeds. This innovative game feeder system is designed with the hunter in mind and built to last in all weather conditions.

Dan Ross, aka “Uncle Dan,” has been manufacturing products for the hunting industry for over 30 years and, as an avid hunter for 60 years, he has the experience and knowledge to design products that work for the hunter. All Ken Ross products are designed by Uncle Dan and his team.

The feeder is rotationally molded of Jerico Plastics Stone Effect PE, using threaded inserts and graphics. All secondary operations are performed using CNC routers.

Ken Ross Incorporated, Rotational Molding manufactures the feeder. Jerico Plastic’s Stone Effect material formulated in uniquely specified colors bring the whole package together into a game feeder that is solidly constructed and very attractive to the hunter and the entire outdoor/hunting industry. All products are manufactured in-house using tooling that is produced in a Ken Ross in-house tooling shop.

This innovative game feeder system is designed with the hunter in mind and built to last in all weather conditions.

the Secret Sauce for Many Rotational Molder’s Success Stories

Much has happened since the last ARMO review of the industry published 4 years ago[1], approximately 9 months prior to COVID-19 taking a stranglehold of virtually every economy around the world. Prior to COVID, the rotational molding industry was in a strong position, with many sectors enjoying healthy growth. Material prices were reasonably stable, helping molders to be competitive with other processes. The industry was surging, and the future looked promising, with one major exception being the tight labor markets in established regions of the world making it exceptionally difficult to fill open positions. Also, the manufactured product value per labor hour ($/hr) was in decline in the US and there was much discussion about the need to automate to reduce labor content and improve productivity[2].

During the COVID years unemployment initially surged and many rotational molding market sectors took a sharp decline. Manufacturing companies came to terms with how to manufacture safely and avoid the spread of the virus. Rotational molders had to react quickly and develop new systems and procedures to protect their employees, which proved to be challenging for this labor-intensive process. Some of the industry’s most faithful employees, who were at or near the end of their careers, decided the risk of working outweighed the gain and opted for retirement. This was the case for many other industries at the time. Global economies went into decline initially and demand for manufactured products waned. It was a very worrying and uncertain time for many molders. The only good news at that particular moment in time was that labor was abundant…but that did not last for long!

Towards the end of 2020, approximately

6-9 months after COVID started, several rotational molding markets started to recover to unexpected high levels of demand. Markets that involved outdoor activities, such as kayaking, boating, camping, etc. remained largely unaffected by COVID and demand for rotationally molded products in these sectors soared. Before we knew it, the labor crisis was back again, and productivity was being greatly impacted by the health and safety measures put in place to prevent the spread of COVID. During this time the sale of rotational molding equipment surged, and many

businesses looked to add capacity. This was caused by increased demand, reduced productivity, and employees not wanting to work overtime, especially at the weekends. Also, mold builders experienced growth from new programs as well as molders needing additional cavities to meet the increase in demand. This was also a time when the lack of industry capacity led to several new companies emerging as they tried to overcome supply chain issues.

From late in 2020 through 2022, molders faced a variety of challenges as they tried to meet growing market demand. One of the greatest challenges came for the supply chain, with many suppliers

6-9 months after COVID started several rotational molding markets started to recover to unexpected high levels of demand.

struggling to obtain raw materials and provide on-time deliveries. As if that was not enough, prices started to escalate for supplied components and raw materials. Labor availability resurfaced again as a major constraint and labor costs increased as businesses competed for the locally available labor. This was a very challenging time for many businesses, but also an opportunity for those who could adapt quickly to grow market share and profitability. It was a time when businesses had to justifiably increase pricing in response to increasing costs, but part of the challenge was that purchased components and materials continue to rise, sometimes resulting in multiple price increases.

Adaptability is Key

The ever-changing environment has resulted in no shortage of challenges for many molders. More recently, some market sectors that boomed during COVID are now in decline due to saturation, and so the cycle of change and the need for adaptability continues. For most businesses managing the decline of markets is much more difficult than managing a surge in business. This is especially true for those molders who added capacity to take advantage of the growth opportunities during COVID. This added capacity will no doubt bring concern to some, as a fall in demand will result in a very competitive marketplace.

Further challenges are now coming from the customer base, who absorbed significant price increases and now would like to see some relief and cost reductions. As molders look forward, one thing is for certain, they will need to have great adaptability to maximize the opportunities that lie ahead. Timely adjustments to business strategies will no doubt ensure competitiveness in an ever-changing environment.

For those trying to maintain a thriving, healthy business, the need for efficiency improvement and cost reduction is clear. It is imperative that molders find suitable technologies to either reduce the amount of labor or reduce the skills needed to manufacture high quality rotationally molded parts. Also, efficiency gains during processing need to be made to minimize machine downtime and maximize arm loading. This will drive technological developments to sustain a balance between the load/ unload cycle time and the other stages of the cycle. While automation is seldom easy, justification for investments is getting easier as labor costs increase and efficiencies decline. With the future likely bringing some harder and more competitive economic times, molders must work to improve these efficiency opportunities to sustain their businesses and be more competitive in the marketplace, which will in turn help to provide growth opportunities.

As molders look forward, one thing is for certain, they will need to have great adaptability to maximize the opportunities that lie ahead.

What is rotational molding?

For those who are reading this article that are unfamiliar with the rotation molding process, the process is best suited to the manufacture of hollow plastic products of various sizes and shapes, with the ability to produce extremely complex geometries. The following information will highlight some of the industry’s most common applications, represented by several product categories. These products demonstrate why rotational molding competes favorably with all other manufacturing process. Here are several product families that are typical rotationally molded applications:

Toys, fitness equipment, and playground structures

Perhaps one of the earliest and wellknown rotational molding applications is children’s toys. Toys, fitness equipment, and playground structures are extremely common rotomolded applications. For soft touch and flexible products, Poly Vinyl Chloride (PVC) is used. This material can replicate the most intricate of details, as seen in PVC dolls heads. Other toy products are manufactured from Linear Low Density Polyethylene (LLDPE) such as the Cozy Car, kitchen play sets, wagons, etc. These products tend to be brightly colored, thin-walled applications with rounded corners that are relatively easy to manufacture. However, to be competitive with other processes the cycle times for these products have to be very aggressive, requiring the application of automation and lean manufacturing methods. Playground structures are also a very common global rotational molding application because of the durability and weatherability of the Polyethylene (PE) material used.

Flotation & Insulated Products

Flotation of plastic has recently become a serious problem for the plastics industry, creating a negative perception regarding the use of plastics. However, PE’s buoyance, water resistance, weatherability, and toughness all help to make it an excellent choice for

rotationally molded flotation products. Fishing buoys, boat ramps, and floating docks are all common rotomolded products. Some floating docks incorporate either PE foam or Polyurethane (PU) foam to increase both strength and buoyance. Kayaks and canoes are also commonly rotationally molded, and often include PE foam. These types of products are typically molded using a rock and roll machine because of their geometry. Insulated coolers are also rotationally molded, and often include PU foam between the external and internal PE layer. This provides excellent insulation properties, allowing the contents of the cooler to remain chilled for several days.

Chemical and water storage tanks

Another very common rotationally molded product is chemical and water storage tanks, which come in a range of shapes and sizes and are globally manufactured using the rotational molding process. Tank volumes can be substantial, up to tens of thousands of gallons. Product design plays an important role to ensure the geometry has sufficient structure to support the tank contents load in the environment in which it operates. Quite often ribs are employed to enhance stiffness of the wall and/or wall thickness is targeted to areas of the tank that are subjected to the highest deflective loads. Typically, High Density Polyethylene (HDPE) materials are used for larger tanks with sufficient hoop strength to meet the functional requirements. Often carousel machines or rock and roll machines are used to manufacture these products. The applications for this type of product family include water storage or harvesting, static fuel storage, and chemical storage.

Material Handling, Waste Disposal

Products & Floor Cleaning

Containers, pallets, IBCs, totes, trash cans, dumpsters, etc. are all commonly rotationally molded products. Cases and containers can be highly sophisticated, for the purpose of carrying and protecting valuable goods. IBCs are commonly used for transportation of chemical products. Trash cans and dumpsters

The process is best suited to the manufacture of hollow plastic products of various sizes and shapes, with the ability to produce extremely complex geometries.

are also common applications for the process and can often incorporate recycled material. Single piece septic tanks can be manufactured using the rotational molding process. Floor cleaning equipment benefits from the process’s ability to mold highly complex geometries that are capable of holding cleaning fluids at elevated temperatures. The recent development of electrically heated molds has further enhanced the process’s ability to achieve uniform wall thickness for these types of applications.

Fuel tanks

Fuel tanks for tractors, construction equipment, trucks, marine engines, generators, compressors, lawn and garden equipment, etc. represents a significant rotomolding sector. Many of these products can be extremely complex in design and include an array of assembled components. For example, agricultural fuels tanks are typically one of the last components to be designed for the vehicle, which results in a very complex geometry to take advantage of any available space to maximize the tank’s volume. These types of applications can include several inserts, bosses, drain plugs, graphics, sending units, etc., all of which must be leak proof. The material of choice for these applications is crosslinked polyethylene because of its UV stability, low temperature impact strength, environment stress crack resistance, and its ability to pass various test requirements such as ECE 34. Crosslinked PE has also been used in combination with other materials that provide excellent resistant to hydrocarbon emission, to reduce fuel weight loss from gasoline tank applications. Many small off-road engines and marine fuel tanks benefit from this material combination to meet environmental regulations.

Custom Applications

In addition to those previously mentioned, there are many other industries and applications that utilize the rotational molding process. These

include: air ducts, cargo beds, blower housings, hydraulic tanks (typically from Nylon 6 or 11), urea tanks, roofs, fenders, consoles, display cabinets, road barriers, traffic signs, laundry carts, furniture, plant pots, mannequins, hoppers, rickshaws, etc.

The Future of the Industry

While the future of the rotational molding process is not in doubt, the challenges the industry has faced over the years have not significantly changed. The process remains unique, but heavily dependent on labor, which is becoming less available, less skilled, and more costly. To be competitive, molders must apply their entrepreneurial spirits to find creative solutions to reduce the cost to manufacture rotationally molded products. In order to do that, one of the most critical factors will be for molders to attract the right talent for these types of manufacturing positions. Staffing, managing the impact of rising labor costs, resin costs, and other inflationary costs are the real challenges that the industry faces today. Therefore, focusing on the work environment, production methods, training, equipment/tools, ergonomics, engagement, teamwork, career growth, and compensation needs to be a top priority to attract good employees and make them feel that manufacturing is a career worth pursuing. An energized and engaged team can do great things when pointed in the right direction. Another challenge for some molders will be the changing competitive landscape, especially in the US, as mergers and acquisitions have been extremely prevalent in recent years. It will be interesting to see if higher interest rates will cause a slowdown in the recent trend.

References:

[1] Rotational Molding Continues to Surge, ARMO Magazine 2019, Alvin Spence, Centro, Inc.

[2] U.S. Rotational Molding: The Road Ahead, RotoWorld®, Vol. XVI, Issue 2, 2020

To be competitive, molders must apply their entrepreneurial spirits to find creative solutions to reduce the cost to manufacture rotationally molded products.

BIG Picture

Jerico is first in quality resins and compounds! We’ve made our name by providing vibrant colors, specialty blends, and recycled black, while focusing on being that one complete source for ALL your rotational molding compound needs. Now you can add natural PE to the list!

Time and again over the years, our team has responded to the changing times with resilience, ingenuity, resolve, and confidence. In true Jerico fashion, we developed sustainable and adhesion compounds, then

blended vibrant colors into both. Make no mistake, we are expanding and are focused on becoming your supplier of choice for rotational molding materials.

As we grow, we look for ways to improve so that we exceed your expectations and help you achieve success! Our mission is to be the go-to resource for resins and compounds that meet your precise specifications, arrive on time, and provide the consistent level of quality you have come to expect from Jerico!

Showcase. Rotational Moulding Product