Ask Dr. Nick: XLPE v. PE heating and cooling cycles

Question: What are typical heating cooling cycles compared between XLPE and PE? 


Dr. Nick Henwood

Dr. Nick: Crosslinkable polyethylene (XLPE) rotomolding grades work in a different way to standard linear low density polyethylene (LLDPE) and high density polyethylene (HDPE) grades.

During the cook stage of rotomolding standard PE grades, two separate things need to be achieved:

  • Sintering – ensuring that powder particles melt and fuse together in a solid mass.  For standard roto grades, sintering is typically completed by the time that the Internal Air Temperature (IAT, the air temperature inside the mold) reaches approx 265 degF.
  • Consolidation – allowing sufficient time and temperature for the gases in trapped air bubbles to dissolve into the molten polymer matrix.  For standard roto grades, consolidation is typically sufficiently accomplished by the time that the IAT reaches 390 degF.

During the cook stage of rotomolding XLPE grades, the above two mechanisms need to be achieved, followed by another additional one:

  • Crosslinking – XLPE grades contain a special package of additives, based on organic peroxides, which form side links and create a network structure from the individual polymer chains.  This network structure provides improved short- and long-term physical properties.  BUT – and it’s a big but – this won’t happen unless sufficient time and temperature is provided.

The requirements for individual XLPE grades may vary, but one general recommendation that I have seen is that, during the final stages of cooking, the IAT should be above 390 degF for several minutes.  An additional processing benefit of the best XLPE grades is that over-cooking does not result in the usual catastrophic loss of impact strength due to chain scission.

I recommend that, if possible, you set up your cook cycles for XLPE using a device that can measure IAT and that you follow the guidelines above, in the absence of anything more specific from your material supplier.  A more rough-and-ready guideline might be to add two or three minutes on to the cook cycle you would use for standard PE,

However –

Depending on the formulation, over-cooking XLPE can result in some undesirable effects, that you will want to avoid.  One common effect is known as coining – the appearance of a locally depressed area on the surface of the part, as though a large coin had been pressed into the surface while the polymer was soft.  Reducing the oven temperature is the usual expedient to eliminate such defects, but then you may affect crosslinking.  Hence my main recommendation, to use available control tools to achieve as much precision in set-up as you possibly can.

Hope that helps; happy rotomolding!

Dr Nick Henwood serves as the Technical Director for the Association of Rotational Molders. He has more than 30 years of experience in rotomolding, specializing in the fields of materials development and process control. He operates as a consultant, researcher and educator through his own company, Rotomotive Limited, based in UK.

“The Seven Stages of Rotomolding” Questions and Comments


Dr. Nick Henwood

As part of ARM’s on-going commitment to member service, we are ramping up our webinar program for 2020.  The latest webinar was presented on March 19 by Dr Gareth McDowell of 493K.  I thoroughly recommend that, if you missed the live show, you catch up with it on the ARM website.

Many of you will be familiar with Dr Gareth’s lively presentation style from his many presentations at ARM conferences. He was able to bring this approach to the very different format of an on-line event and, as a result, we saw a high level of reaction from the live audience, in terms of comments and questions.

Unfortunately, we simply ran out of time to address everyone’s needs, so I’m doing a wrap-up via my Technical Director’s Blog.  The length of my Blog reflects the number of questions, but feel free to dip in and out of it, if you don’t have time for a long read!

Thanks again to Gareth for a really excellent webinar.   Continue reading

President’s Message: ARM is adapting to unprecedented change


ARM President Rick Carlsen

To give this message context, I am writing this on 03/18/20.  The US has 6,519 confirmed COVID-19 cases, there have been 204,000 cases worldwide, and the DJIA is at 20,315.  Schools, restaurants, bars, and other “non-essential” businesses are closed nationwide. Tom Brady just signed with the Tampa Bay Buccaneers; the world is in chaos.

We made the decision to postpone the Spring Executive Forum three weeks ago today.  At the time, there were fewer than 500 confirmed cases in Italy. We were hearing rumblings of border closures and quarantines.  As crazy as it felt, we thought there was a risk of ARM members getting stuck abroad, so we made the decision to postpone. What seemed like a possible overreaction three weeks ago seems like a simple decision today.  Things are changing quickly.

As we are facing unprecedented changes in our daily lives, ARM is working hard to adapt to this fluid situation.  We are working to determine how ARM can deliver value to its members in the world of social distancing. Personal interaction between members will be limited for a period of time, which is very unfortunate given that we constantly hear that “networking” is one of the greatest ARM values.

ARM has hosted webinars for more than 10 years.  These sessions are free and available online to our members to view at their leisure.  This has proven to be a successful way to interact with our members, and we see this as a continued viable meeting method in the near term.

In addition to webinars, ARM has built an impressive knowledge library that is accessible to our members.  The knowledge library has information on almost any topic that applies to your business. I encourage you and your team to explore its offerings. 

In my last letter, I wrote that ARM’s goals remained unchanged; we are dedicated to making incremental and sustainable changes that increase the value that ARM offers its members.  The COVID-19 pandemic doesn’t change this. ARM’s delivery methods and personal interactions are going to be different for a period of time. ARM will try some new ways to interact with its members, some of which will work and some that will teach us what to do better next time.  

Finally, ARM is on solid financial ground.  We have worked diligently to build cash reserves in preparation for times like this.  We have analyzed our projected cashflows, and we know we will weather this storm and come out the other side in great shape.

Thank you for your continued support of ARM!


Rick Carlsen
Solar Plastics, LLC
ARM President

Ask Dr. Nick: Warpage in a polypropylene tank

Question: In a cylindrical tank made of PP powder, we have experienced a problem of warpage (internal and external waves). I wonder if you could give me your technical opinion. The inside part of the mold is welded with an additional metal stripe and in this part of the mold we are facing warpage in the molded part. The warpage area is focused in the middle part of the welded metal stripe. In the warped area, the wall thickness is between 7.5 – 8.5 mm. In order to eliminate the warpage problem, our customer has added externally a metal plaque to prevent overheating. The part is cooled up to 80-85 degC (176 – 185 degF) inside the mold. Then, the part is moved from the mold and is left for cooling in the environmental temperature.


Dr. Nick Henwood

Dr: Nick:  I’ll try to give an opinion on this problem. 

  1.       I’ve previously seen warpage problems when molding a particular grade of PP.  The shape I was molding was a simple cylinder. The material supplier told me that PP has “natural lubricity”, by which I understood that something in the polymer migrates to the mold surface and provides what amounts to an internal release agent.  However, I have successfully molded many other grades of PP, without seeing the problem.
  2.       Generally, PP shrinks less than PE, so you would expect that warpage problems (which are caused by unequal shrinkage rates in different sections of the molded part) would be less.
  3.       Warpage effects tend to occur more often with thick parts; at 7.5 – 8.5 mm, I would consider your part to be pretty thick.
  4.       The area of the mold containing the welded metal stripe may result in a different heating condition compared to the rest of the mold surface.  This may result in a lesser or greater wall thickness building up at the stripe. It’s not clear from your description which it is, although the fact that the problem was fixed by reducing the heat to the stripe area (by adding the external metal plaque) indicates that the stripe area was previously heating up more than the rest.  Did you measure the wall thickness of the part in this area, compared to the rest of the part?  In any case, thickness variation around the part is another cause of warpage.
  5.       You’ve not mentioned anything about mold release agent (mra); your choice and level of application may be a factor.  If the PP grade you’re using has this natural lubricity (see note 1 above), then reduce the level of mra applied. You can immediately reduce the release properties of an existing surface (ie one which already has mra applied) by gently abrading with a scotch pad or similar non-metallic product.
  6.       Slower cooling can reduce warpage; you don’t specify how you cooled or the cooling rate.  In extremis, don’t apply any external cooling and allow the mold to cool naturally in ambient conditions.  Worth trying, just to see if it helps, even if this is not practical in production.

I hope the above list gives you some pointers to the problem.  Whilst the root causes of warpage are similar across production, the way these causes come together to manifest a particular warpage problem can be complicated.

Dr Nick Henwood serves as the Technical Director for the Association of Rotational Molders. He has 25 years-plus experience in rotomolding, specializing in the fields of materials development and process control. He operates as a consultant, researcher and educator through his own company, Rotomotive Limited, based in UK.

ARM Tours Italy: Attendee Info

ARM regrets to announce that we will be postponing our tour of Italian rotomolders and our collaborative meeting with IT-RO, the Italian rotomolding organization. The meeting had been scheduled for March 29 – April 3.

We are working with the venues in Italy and those we have booked for our next spring meeting to determine when we will reschedule. We expect to hold the meeting in 2021 or 2022 and will make an announcement in the coming weeks.

Details for the postponed meeting follow…


More than 60 attendees (including more than 25 ARM members) have already registered for our unique event in Italy.

The meeting begins with a tour of the rotomolders of high-end, complex parts in northern Italy. Then we join our Italian counterparts for a day and a half of education and networking on Lake Garda.

Below we’ve included some information about the meeting for planning purposes. We’ll update this post as the event approaches.


March 29: Arrive in Milan; Overnight at Villa Malpensa Hotel
March 30: Tour Rototech and Metallurgiche Cornaglia; Dinner included at Roof Garden in Bergamo; Overnight at Mercure Hotel in Bergamo
March 31: Tour Persico and Acerbis; Overnight at Hotel Caesius
April 1: Tour Ve.Ca and Moulding Services and the Ferarri Museum; Overnight at Hotel Caesius
April 2: Conference at Hotel Caesius; Dinner included at Hotel Caesius
April 3: Half-Day Conference and Optional Wine Tour

  • Lunch is included on tour stops and during the conference.
  • Our Sunday night hotel, Villa Malpensa Hotel, is located a few minutes away from Milan’s Malpensa airport. The tour will depart from Villa Malpensa Hotel early Monday morning.
  • If you’re departing Italy from Hotel Caesius, Milan’s Linate airport is the closer of the two Milan airports. Verona airport is the closest to Hotel Caesius but offers fewer flights.

Airport Transfers and more
The Hotel Caesius offers private cars and coaches to the airports and the train stations. Their price list is available here. In the next couple of weeks, we will send a form to see if it’s feasible to organize group transfers to the airport.

Education Program
We are organizing the education sessions with our Technical Director and IT-RO. A key portion of the program will be based on our group’s feedback from the tours. ARM members will complete comment cards after each part of the tour and Nick Henwood will use that feedback to lead a discussion during the conference about what we liked, what we learned, and what we want to know more about. We’re making good progress and will be able to share more about the remainder of the program soon.

You should plan for your own voice/data cellular service while in Italy. However, we are ordering multiple pocket wifi servers. We’ve never used it before but hope it will improve connectivity for everyone on the tour.



President’s Message: ARM’s approach, offerings, and goals remain steadfast



ARM President Rick Carlsen

In an attempt to understand how long New Year’s Resolutions last, a social networking firm called Strava analyzed over 30 million fitness records from its users.  The results show that most New Year’s Resolutions start to derail on the second Friday in January. This year, most people’s resolutions lasted just 10 days.


A reason for short-lived resolutions is that many of them are viewed as temporary, thus, expendable.  To make sustainable changes, experts advise that you should make small additions to your routine that don’t result in a perceived hardship.

I am happy to report that ARM made 0 New Year’s Resolutions this year.  Continue reading

ARM Members Can Watch These 65 On-Demand Roto Training Webinars

Updated: As of June 2020 there are now more than 85 webinars available to members. Read the updated post.

ARM webinars were viewed 3,600 webinar times in 2019.  This number combines live webinar views — where members were able to partake in Q&A — and on-demand webinar views — where members were accessed our 10+ years of webinars at their convenience on the ARM website.

We have offer 65 webinars available on-demand for members. Members can access all of these titles immediately. Non-members can join here.

In addition to a variety of new webinar topics in 2020, we plan to organize a new series based on the Introductory Guide to Designing Rotomolded Parts.

  • Operator Training Program (25 Videos) presented by Nick Henwood, Dru Laws, and more Click for the detailed contents
  • Burner Maintenance presented by Adam Covington
  • Considerations When Light-Weighting Rotomolded Parts presented by Henry Hay
  • Cooling Fixtures presented by Ron Joannou Jr. and Joey Morsi
  • Determining Your True Cost presented by Steve Osborn
  • The Effect of Pigments and Warpage on HDPE Rotomolded Parts by Mike Haubert
  • EPCRA Reporting & Combustible Dust (with Roto 101 Intro) presented by EPA & OSHA
  • Finishing Parts with Robots (Case Study) presented by Dru Laws
  • Finishing Series (4 videos): Secondary Finishing Operations, Graphics, EPS Molding, and PU Foaming presented by Jason Brownell, Rick Carlsen, Corey Eystad, Nick Henwood, and Scott Saxman
  • Finite Element Analysis: The Basics presented by Michael Paloian
  • Improving Rotational Molded Insert Performance presented by Glenn Larkin and Jon Ratzlaff
  • In-Process Rotational Foam Molding presented by Dru Laws
  • Infrared Thermography presented by Bill Spenceley
  • Lengthening the Life of Your Mold presented by Tony Short
  • Making the Most of Trade Shows by Melissa Shearer
  • Making the Most of Your Marketing Budget presented by Melissa Shearer
  • Mold Clamping Methods – Pros and Cons presented by Erik Adams and Bob Mueller
  • Mold Release presented by Even Silo & Scott Waterman
  • Prop 65 for Rotomolders presented by Mike Haubert
  • Proper Sampling Techniques presented by Josh Hunsberger and Dave Loeffler
  • Rebranding Your Business (Case Study) presented by Tom Innis
  • Resin Rotomation by Rob Miller
  • Rotational Molding & the Evolving Structural Part Processing Business presented by Dr. Peter Mooney
  • Roto 101 presented by Rick Carlsen & Ron Joannou Jr.
  • Safety in Rotomolding & OSHA Compliance presented by Dave Schwoerer
  • Save Energy & Save Money presented by Bill Spenceley
  • Selecting the Right PE Grade for Your Part presented by Nick Henwood
  • Solve Cosmetic Part Problems presented by Jon Ratzlaff
  • Stiffness Models and Options for Multi-Layered Parts presented by Dr. Nick Henwood
  • Test Method for Flowability (Dry Flow Rate) of Polyethylene Powders Using a Specified Funnel presented by Ron Cooke & Jon Ratzlaff
  • Ten Actionable Business Topics by Tom Kammerait
  • Troubleshooting Your Rotomolding Operation from a Shop Floor Perspective presented by Ron Cooke
  • Turning a 4% Bottom Line into a 10% Bottom Line presented by Al Bates
  • Understanding the Molding Cycle presented by Gareth MacDowell
  • Unwanted Holes in Rotomolded Parts by Nick Henwood
  • Vent Plug Materials, Techniques, and Installations by Sandy Scaccia
  • What Does Internal Air Mold Temperature Have to do with Quality presented by Gareth McDowell
  • What’s Your Problem (2 videos) presented by Ron Cooke & Sandy Scaccia

President’s Message: The People of ARM


ARM 2018 – 2019 President Dru Laws

As my final message as the president of ARM, please forgive a different (and more personal) approach.  Instead of talking about the processes and programs that make up our association. I’d like to focus on the people that populate it.

It has been my complete honor to serve all of you as ARM President.  You have each made it a great experience for me! I am particularly grateful for those whom I get to rub shoulders with on the Board of Directors.  You can all rest assured that each one of these board members is an honorable industry ambassador. And a sincere thank you to those who serve on and lead the committees.  It’s encouraging to watch so much time freely and selflessly given to better the association. I would highly recommend you each consider how you can be a part of these fine groups of individuals and volunteers.

I can’t help but express my gratitude for the ARM leaders of yesteryear.  What an amazing community they helped build. I feel fortunate to have been able to carry that leadership baton for the past 2 years, and I am excited to now pass it on to those better qualified than I to carry us onward and upward.

And a big thank you to the amazing team that manages our association, on a day-to-day basis.  They do far more than any of us realize.

I love the variety of meetings the association holds throughout the year.  Some of those are remote, while others are in person. Regardless of the format, I love them mostly because of the people I get to associate with … you.  I look forward to shaking hands with new faces, and exchanging stories with old friends.

As I reflect on my ARM membership, I’m reminded of an old quaker proverb … “Thee lift me, and I’ll lift thee, and we’ll ascend together”.  This has certainly been my experience. Every time I extend help to someone else in the industry, I seem to benefit more so. What a great personal investment it has been for me, and I owe that to so many of you.

Now, in conclusion, please allow a short and heart-felt two-word benediction.

Thank you!

Dru Laws is the President of ARM and the Senior Vice President of Seljan Company in Lake Mills, Wisconsin.

Connect with Exhibitors in Houston


We asked our 2019 Annual Meeting exhibitors to describe how they supply or support the rotomolding industry and the contact person in Houston. We encourage you to contact them to set up a time to meet during or after the show.

Rick Jaehnert

Brilliant Solutions Management Partners
Jim Braeunig
BSMP represents Promosal a Spanish CNC Rotomold supplier.

Brian Steenbeke

Chevron Phillips Chemical Company
Shauna Smith

Custom Plastics
Charlynne Eberhart
Injection molded spinweld fittings, patches-sensors-caps-threaded-custom.

Diversified Mold & Castings
Vince Costello
Rotomolding tooling supplier including cast, CNC, fab, and rework molds .

Dow Chemical Company
Corey Newsom
Providing the rotomolding industry with PE resins and expertise.

Entec Polymers
Pat Gallo
PE pellets, powder, color and specialty compounds for rotomolders.

ExxonMobil Chemical
Kevin Jamieson
A leading supplier of polyethylene resin to the rotomolding industry

Ann Rowland
Rotational molding machines, platforms, RotoLog, dispensers, mixers.

Foam Supplies
Ann Roche

Hightower Products
Jake Richards

Zachary Utz
Two component polyurethane foam and dispensing solutions

Jerico Plastic Industries
Steve Copeland
Custom PE compounds for specialty rotational molding applications.

Natalie Nichols
LyondellBasell is one of the largest plastics and refining companies in the world.

M. Holland Company
Brian Brantley
A business partner and stocking distributor for Nova Roto Products.

McCann Plastics
Jay Reed

McLube Release Agents & Lubricants
Evan Silo
Release agents, PU foam release, assembly lubricants, EP machine lube.

Mosaic Color & Additives
Mike Williams
Pre-colored resins & dry color Highest Stiffness -Fast Cycling-Low Heat Gain

George Winter
ExxonMobil Rotational Molding grade Polyethylenes

Nexeo Plastics
Owen Hodges
We connect you with high-quality material for rotomolding processes.

Norstar Aluminum Molds
Robert Mueller
Manufacturer of Cast & Machined Rotational Molds.

NOVA Chemicals Inc
Doug Biela
A complete range of polyethylene rotational molding resins.

Orenda Automation
Matthew Tornow

Paladin Sales
Terrry Gillian
EZ Logger, RotoLoad, Permanent Graphics, AutoMatic Mold Jacks.

Sergio Zilioli
From product engineering to molds manufacturing & testing

Glenn Iken
Wide range of high-quality Rotomolding Compounds and new developments.

Jim Hummel
World-class pulverizing systems. Disk sharpening services, mixers, silos.

Quantum Polymers Inc.
Anthony Kozelka
Branded Distributor of ExxonMobil Resins for Rotational Molding

Reliance Mixers
Kyler Berhost
We increase quality of blend through high intensive mixing equipment

Rock Lake Robotics
Sam Scott
Supplies rotomold manufactures w/ an automated secondary cutting process

Rotaloc International, LLC
Steve Harris
Inserts, Bulkhead Assy’s, Pins, Sleeves, Custom Components, PTFE Vent Tube

Mr. Yves Gervais
Rotational Mold Maker. Cast, CNC, Fabricated. Aluminum Foundry on-site.

Jose Gomez
We supply high quality resins exclusively for the Rotomolding Industry.

Matthew Jeffries

Solvay Polymer Additives
Tammy Pate
Polymer Stabilization solutions for rotomolding resins (PE and PP).

Stoner, Inc.
Larry Whittemore
Mold Releases, Flow Promoter, Mold cleaner, and Parting Line Protectant.

Michel Truax
Our company manufactures state-of-the-art rotational molding equipment.

Vive Marketing
Teresa Schell
Elevate brands to increase sales through updated marketing strategies

Wenling Rising Sun Rotomolding Technology Co., Ltd.
Sharon Zhu
Rising Sun Rotomolding main business is rotomolding machine, mould.


Rotomolding Education Sessions at the ARM Annual Meeting in Houston

ARM has announced the complete education schedule for our Annual Meeting in Houston (October 27-30). We have already exceeded last year’s attendance and we’re on track to have a very impressive group.

Patrick Schwerdtfeger


Patrick has been a full-time professional speaker since 2007. He got his start after his “Beyond the Rate” podcast (focused on mortgages and the real estate industry) gained popularity in 2006. During the subprime ‘mortgage meltdown’ (2007) and ensuing financial crisis (2008), he was interviewed regularly on mainstream media and soon began speaking at business events and conferences. He covered developments in the collapsing financial markets and, before long, spoke about the burgeoning field of podcasting and social media as well.

Today, Patrick is a business futurist specializing in technology trends including big data, artificial intelligence and blockchain. He’s the founder of Trend Mastery Inc. and host of the Strategic Business Insights video blog. Trend Mastery is a strategic consulting agency, identifying a world of transformational opportunities, and Strategic Business Insights has over 25,000 subscribers and five million views on YouTube.

Outside the Box: Smart Containers
Jose Gomez, RotoPolymers


Thought of as inconsequential to our pursuit of a more modern, efficient process, boxes remain the most common (though not the most practical) vessel in which Rotomolders store resin. This presentation explores alternative solutions. From small to bulk packaging, new developments turn containers into active, purposeful parts of our operation which help address some of our industry’s current concerns, such as labor, productivity, environmental impact, and of course, cost efficiency. What if a bag could absorb or bypass steps in our process, eliminating human error and waste? What if a container could provide useful, real-time intelligence on inventories and even optimize purchasing? What if these were not things of the future, but available tools of simple application? These are some of the topics we will elaborate on, proving that small choices can lead to big improvements.

Rotomolders will take away a path towards significant savings and process optimization that, unlike most, can be taken easily, immediately, and at very little or no cost to them.

Industry 4.0 Will Rotomolding Be Left Behind?
Johan Portagent, AMS Belgium

The Industry of the Future 4.0, the 4th industrial revolution, will certainly change manufacturing. This is a real industrial revolution with the arrival of Automation, Predictive Maintenance, and Big Data. The fourth industrial development is coupled with major changes in the world: energy, environment, organizational, and societal interests. The human will be at the very center of this industry with a new role: Digital will be between machines and workers. New jobs will be created and training will be strategic in organizations. It’s an amazing opportunity for the rotomolding industry to enter a new age to bring new opportunities: innovation (process and resin developments, new kinds of studies), competitiveness, productivity, customer focus, service focus, a factory networking suppliers and clients, high flexibility, a clean plant oriented to sustainability, an automatized plant to get rid of hard work for people. Let’s have a look to see if the rotomolding industry can enter soon into the industry of the future 4.0.

What If?
Rob Miller and Lisa Allong, Wittmann Battenfeld Canada Inc.


What if someone could explain Industry 4.0 as it can apply to roto? This presentation will break down the term Industry 4.0 and highlight key opportunities for rotomolders. The presenters will clearly identify, define, explain ROI and provide 10+ key examples of mature automation ideas that would exemplify the adoption of the 4.0 revolution into the roto industry. The presenters will draw from their experience in the robot world and the associated automation to employ proven industrial products and theories. Molders will leave with an understanding of a cross-section of basic, mature automation concepts that they can investigate, develop, and potentially employ within their facilities to make them more efficient, reduce costs, save labor, and genuinely take them into the 4th industrial revolution. 

Dry Blending Study
Dr. Nick Henwood, Rotomotive/ARM Technical Director

Funded by the Roy Crawford Rotomolding Educational & Development Foundation, this study examines the effects of pigment dry blending on material strength. It builds on previous research and concentrates on the effect of pigment type on the retention of impact strength.

Pigment warpage and interactions with HDPE Rotomolding resins
Mike Haubert, Mosaic Color and Additives

In order to provide rotomolders with a deeper understanding of how pigments affect their process, this presentation will report on new research comparing various pigment choices in HDPE. Shrink, warp and impact have been measured to compare how individual pigments affect performance.

Keeping Powder and Pellets Out of the Environment
Doug Biela, NOVA Chemicals

In a time when plastics and the environment are on the minds of consumers, politicians and our customers, this discussion will highlight the paramount importance of keeping powder/pellets out of the environment.  It will cover management systems and tools that rotomolders can employ to ensure that their plants are not putting plastic where it’s not supposed to be.

Rotomolders will gain an understanding of some actions they can take immediately to improve their powder/pellet management and reduce or eliminate environmental impact.  They will also learn about Operation Clean Sweep® and how to join other rotomolders to take the pledge to eliminate pellet and powder leakage into the environment.

An Industry Profile of Rotational Molding
Troy Meinhard, KnowHow Strategy & Analytics

Comprehensive market intelligence on the rotational molding industry is limited.  Low product volumes make data challenging to collect and general plastic industry market research doesn’t address the rotational molding industry in detail because rotational molding is <1% of annual resin consumption.  By combining existing sources of data in an analytically rigorous way and supplementing it with creative and gritty data acquisition from non-traditional sources, ARM and KnowHow have created an industry profile that segments and sizes the producers and consumers in the industry along multiple dimensions.

Members will have a data-driven understanding of the structure of the industry. This market intelligence is critical context for:

  1. Sales planning

  2. Growth strategy development

  3. Competitive analysis

  4. Baseline for understanding changes in the industry (e.g., the impact of consolidation, generational transfer that results in sales to strategic and financial investors)

  5. Other business decision-making

Rotomolding Application in Historical Preservation and Artifacts
Oliver Wandres, MAUS GmbH
Alongkorn Kanokboriboon, SCG ICO Polymers

Case Study on converting very traditionally wood carved artifacts to beautiful rotational molded products which — with a great amount of post-molding work — become unique pieces of artwork, that on a first glance nobody would or could associate with rotomolding.

In close co-operation between the end customer, SCG ICO Polymers and MAUS GmbH were able to develop the sensitive transformation from historical and religious wood carved objects to very unique examples of what is achievable in rotomoulding when combining handcraft, high-quality mold making, the latest mold making technologies, and out of the box thinking.

This case study provides an example of the infinitely versatile application possibilities of rotational molding.

Designing for the Future
Martin Spencer, UniqueRoto

The presentation looks at how rotational molding has changed over recent years with new machinery and materials now available to molders. It will look at how, if grasped, by molders these developments open up many new markets and opportunities giving those designing considerably more freedom to exploit the process.

Case Study on Slushing Tests for Diesel Tanks
Celal Beysel, Floteks

The market for rotomolded diesel fuel tanks and Adblue [urea] tanks is growing globally. Further market penetration for Commercial Vehicles with irregularly shaped high volume tanks holds much potential & promise for rotomolding. Floteks has developed patented technology to mold integrated baffles; these have been tested with sloshing simulations and experiments, accelerating the tanks to +/-0.8 g.  This technology also enables to mold an integrated fuel and AdBlue tank separated by a 100% sealed baffle.

Persico & Kaercher’s Rotomolding Evolution
Sergio Zillioli, Persico

This presentation will investigate the evolution of the relationship between Persico and Kaercher over more than 15 years. How and why the technology used in production has changed from cast aluminum
tools to CNC machined tools to electrically heated DTH tools, from gas heated ovens to Leonardo oil heated machines to ‘Smart’ machines. The presentation will include a video of these technologies in use within the Kaercher factory in Germany and an interview with Kaercher production manager outlining the advantages and disadvantages of the various systems. The presentation will also look at fully automated systems developed by Persico including Leonardo-based composter production and animations of a fully-automated production cell in production.

Automation Case Study
Rotoline and Toter 

Presenting the current project between Rotoline and the Toter group where a fully automated rotational molding machine is running at Toter in order to help them achieve targets on safety and liability, labor issues, material loss, scrap, and consistency. Toter will explain the process of how and why they decided to look further into automation and what role this machine plays in their business model. Rotoline will speak on taking the process and creating equipment that will better serve the molder as well as the end customer for a better-rotomolded product. This presentation will open the eyes to those who have not been exposed to how technologically advanced the industry has become and where the industry is heading.

Modeling the Rotomolding Process: Practical Benefits and more
Hassan Riaz, NOVA Chemicals

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In this presentation, the complete functionality of RotoSim as a process modeling tool is explored at the NOVA Centre for Performance Applications. Mainly, the importance of model inputs such as machine conditions, resin properties, and mold drawings will be discussed as well as a protocol to follow for molders to build confidence in RotoSim as a technical tool. Furthermore, this presentation will outline how to practically apply modeling results from RotoSim, such as PIAT curves, thickness distributions, etc. to guide molder’s manufacturing processes.


Alternative Materials in Rotomolding Today
Ron Cooke, ExxonMobil Chemical Company
Ron Joannou Jr., Formed Plastics Inc.

This workshop will provide rotomolders with an understanding of materials other than polyethylene that are successfully being used in rotomolding operations today. The discussion will include the attributes molders are looking for in their parts and which materials may work for them.

Internal Cooling
Martin Spencer, UniqueRoto
Dru Laws, Seljan Company
Daven Claerbout, Dutchland Plastics

Environmental Panel
Doug Biela, NOVA Chemicals; and Jon Ratzlaff, Chevron Philips Chemical Company

Hidden Costs Only Front Line Personnel See and How Making Toast Can Find Them
Ken Bather, Hedstrom Plastics

This workshop is an interactive program using the Shingo Prize-winning Introduction to Continuous Improvement & Lean Principles video combined with actual rotomolding plant operations. A great first step to having your front line operators tell you where your hidden costs are lurking. This workshop is the icebreaker to get over the initial hump of the “we’ve heard it before” attitude by making a relatable link between something everyone can actually relate to and the often unrelatable process of Lean Continuous Improvement. It nails the 7 wastes by showing how to find them with real rotomolding operation examples and gives you the opportunity to take the information back to your team. Introduce or reinvigorate lean concepts to your shop floor production team without onerous terms, paperwork, or oversight. This is a simple way for the hidden talents of your team members to shine through and save you money and lost margins.

How Does Mold Release Affect Warp?
Evan Silo, McLube Release Agents & Lubricants
Larry Whittemore, Stoner

Incorrect mold release application is one of the top causes of part warpage. Almost all of the attendees at this year’s ARM regional meetings on warp told us that they were eager to take what they learned about mold release and bring it back to the shop. So we’re bringing the session back to our Annual Meeting in Houston.

This presentation will address curing of mold release, properly applying release to the mold, and more.

Pigment Discussion
Mike Haubert, Mosaic Color and Additives
Nick Henwood, Rotomotive Inc.

What’s Your Problem?
Ron Cooke, ExxonMobil Chemical Company
Sandy Scaccia, Norstar Aluminum Molds

An ARM tradition: troubleshoot your problems with your colleagues and industry experts. This is a simple and effective workshop that can change your operation, help you reduce scrap, and reduce significant expenses.

What’s Your Problem en Español


Rotomolding 101 in Spanish
October 27 8:00am

This full-day seminar will be taught in Spanish and serves as an introduction to the rotomolding process taught by a team of rotomolders from Operadora Miraplastek.

Advanced Design Methods
Michael Paloain, Integrated Design Systems
October 28 8:00am

This intensive four-hour seminar presented by Michael Paloian will focus on integrating industrial design with rotational molding to optimize a product design for the user and manufacturer. Attendees should be familiar with basic rotational molding design considerations. The seminar will review design considerations from the early stages of the design process, which are typically conceived by industrial designers and describe the progression of the design process through to a production design. These phases of development will be presented by referencing actual case studies as well as good engineering practices.

More detailed descriptions to come. Register for the Annual Meeting today.