The objectives of ROTOFLEX are to advance the competitiveness of the European SME-rotational moulding sector through:
- Development of an automatic feed system that can be retrofitted to standard rotomoulding machines that will confer 30% reductions in cycle time, with 30% energy savings
- Quantification of the rotomoulding process through the use of simulation software, leading to improved process understanding, control, and product quality
- Development of processes using the automatic feed system to make advanced composite products
- Development of processes using the automatic feed system to make advanced multilayer products
- Development of processes using the automatic feed system to deliver controlled internal mould pressurisation facilitating the use of engineering resins and sustainable resins for value added products
Rotational moulding is the process of choice for the manufacture of large hollow, seamless products, such as automotive components (10% of the rotomoulding market), tanks (27%), containers (15%), toys (20%) and kayaks (5%), usually in polyethylene for a wide range of sectors. It is a very competitive alternative to blow moulding, thermoforming, and injection moulding, using simple and relatively inexpensive moulds, and offers designers the opportunity to achieve the economic production of low-stress articles, with uniform wall thickness and in complex shapes (undercuts and intricate contours are difficult with competing technologies). The principle of rotational moulding of plastics comprises introducing a known amount of plastic in powder, granular, or viscous-liquid form into a shell-like mould. The mould is then rotated whilst heating and cooling.
The European rotational moulding sector has an estimated annual turnover approaching €3 billion. Europe is one of the world leaders in the field, with around 450 processors, mainly SMEs continual innovation and the expansion of rotational moulding into new areas and applications is necessary in order to maintain the EU rotational moulding community at the forefront of this rapidly increasing market.