Issuu

Expanding Horizons

Rotational Moulding: The Potential

Speciality Polyethylenes

Plastic Materials Create Value

Pioneering Sustainability Matrix Polymers

Groundbreaking Design Moonlight

Contemporary Design Frontier Polymers

Green Hydrogen Systems APEX

Automotive Industry Floteks

Credits

Martin Coles, Group CEO, Matrix Polymers

From the Editor

Introducing Expanding Horizons, the second edition of the Matrix Polymers Magazine.

The aim of this magazine is to help educate and inform designers, rotomoulders and OEMs about the endless possibilities that the rotational moulding process has to offer.

Many people are unaware of the very wide range of products that are manufactured and our goal is to inspire and encourage the development of new applications.

Hopefully our selection of case studies of products made by some of our customers around the world will provide valuable insights and will encourage you to explore and push the boundaries of what is possible with this technology.

With its flexibility, durability and relatively low production costs rotomoulding offers many advantages over more well-known plastics processes.

I hope you enjoy reading Edition 2 and it serves as a catalyst to help you develop your own ideas. Enjoy the issue.

Plastic Materials Create Value

Expanding Horizons is a magazine that tells a series of stories about the special relationship that Matrix Polymers develops with its manufacturing partners. Stories that arise and develop in different sectors and countries, which are confronted with different problems and which often pose complex and, at the same time, extremely exciting challenges. Expanding Horizons tells these cases in depth to testify the key role Matrix Polymers plays in the value chain that revolves around rotational molding.

Speciality Polyethylenes

Our team of industry experts, have a wide range of skills and knowledge, we collaborate with our customers from ideation to creation helping partners identify new possibilities that are aligned to market trends and insights. Matrix Polymers has an experienced team of people in all aspects of rotational moulding, from polymer chemistry to polymer design, compounding to grinding, rotomoulding to colour matching and logistics to customer services.

01 Matrix Polymers Pioneering Sustainability

The

point of view of

Martin Coles, Group CEO

We’re seeing exciting trends emerging in the rotational moulding industry, with an increased focus on sustainability and environmental responsibility.

In our industry, the term sustainability is one of those buzz words that is thrown around a lot and it is important for us to think about its meaning and how it applies to our business.

There are many definitions, but the one I like most is –“Sustainability is fulfilling the needs of the current generation without compromising future generations’ needs.”

Less material and more efficiency

Several rotomoulding companies are now exploring alternative energy sources, including biogas and renewable electricity, to reduce their carbon footprint. As we begin to realize that resources are finite, the concepts of reducing waste, using fewer resources, and recycling have become more and more common, and rotomoulders and their suppliers are now discussing what else can be done to reduce waste and improve resource efficiency.

How does this apply to rotomoulding?

Among the most obvious topics to discuss when it comes to sustainability, include climate change, carbon dioxide emissions, and Net Zero. As most rotomoulders use natural gas, the efficiency of converting this non-renewable fossil fuel into rotomoulded parts is poor. In general, the actual production of the final product consumes only 5 - 8% of the energy used by conventional machinery. This is why our industry’s recent focus on improving energy efficiency and heating molds directly is a welcomed development.

Limit the spread of plastic

In my view the third main area of focus when considering sustainability in the industry is plastic pollution. As plastic pollution in streams, rivers, and oceans continues to grow, it is evident that we are “compromising the needs of future generations” as a result. The plastic pellets and powder handlers have a major responsibility not to contribute to this problem, and everyone should take part in programs such as “Operation Clean Sweep” and do everything they can to prevent plastic from entering the environment.

Manage the end of product life

Another issue that is being forced onto the agenda is the end of product life. While I was in New Zealand recently, I discovered that some moulders had developed recycling programs for old rotomoulded junction boxes and water storage tanks.

Sustainability as a mission

As a company that specialises in materials for rotational moulding, we take this subject of sustainability very seriously and have several projects, mostly related to materials that we are working on in different regions of the world. Indeed, we are supporting one of our employees Jake Kelly-Walley in studying for a PhD titled “A Sustainable Approach to Materials for Advanced Rotational Moulding Applications” at the Polymer Processing Research Centre at Queen’s University in Belfast.

Want to know more about the work we’ve been doing to help reduce energy and material consumption, to develop bio-based polymers, and incorporating post-consumer and post-industrial waste into consistently performing rotomoulding materials?

sales@matrixpolymers.com

matrixpolymers.com

Moonlight Groundbreaking Design

Moonlight Lumieres was founded in 1997 with a vision of creating a unique light diffusion and ambient lighting. Inventing the first PE globe lights on the market, this product won numerous design awards, such as Design Plus, Form, Good Design Award, IF Design Award. In addition to being able to be used indoors and outdoors, Moonlight lights can be seamlessly integrated into any environment, including gardens, architecture, or even wet areas. Moonlight has been the epitome of atmospheric light, innovative design, and maximum robustness and durability for more than 20 years. To ensure quality and robustness, all globe lights are manufactured at the company’s headquarters in Schwörstadt, Southern Germany.

A fundamental value of everyday life is the quality of light: Moonlight and Matrix Polymers collaborated on this basis to create high-quality, high-design lamps.

> Moonlight Battery Light

Bring Nature’s Illumination to Life

Human feelings are greatly influenced by light, whether it is in living rooms, gardens, architecture, or at social events. A harsh light is created by many light sources that does not exist in nature. Moonlight aims to mimic natural light as closely as possible, both in terms of design and visual effect. It was not possible to achieve the softness and indirect nature of a Moonlight, as well as its robustness, using glass.

Timeless Design

An excellent design outlasts the spirit of the times, which is why Moonlight luminaires are still manufactured today in the same form and quality as they were in 1997. Their lighting characteristics create a nuanced and atmospheric environment that is appreciated by architects worldwide. From its inception until today, Moonlight has strived to create lamps that are timeless, capable of remaining current over time, and innovative in terms of light output.

> Ground-Anchored Moonlight Lamp

Unmatched Ambience

In addition to light intensity and color temperature, light distribution and diffusion has a decisive influence on mood, space reception, and ambience. With its soft, even light characteristics, every environment is filled with an unparalleled feeling of calm and tranquility. Moonlight is the emblem of atmospheric indoor and outdoor lighting for designing with light. The Moonlight lights are available in a variety of sizes, colors, and mounting systems to meet every design requirement. Viewers are almost invisible to all types of base mounts.

New Lighting Scenario

Moonlight’s 5 mm thickness of rotomoulded PE creates a new experience in light diffusion and durability. A Moonlight environment provides a base level of illumination for all elements within it, without blending humans into it. Shadows cast by ambient light are generally soft and less defined since there is no strong directional light source. By cutting the globe and recessing the socket, it can be fixed on the ground seamlessly and without any visible base at all.

> Moonlight Hanging Lamps

> Moonlight Lamp Hemisphere

Safe and Resistant Lamps

It is by design that Moonlight lights are very well protected against moisture and dust up to IP68. The tread that connects the globe and the socket is integrated into the shape and mold. Due to the use of PE in the socket, a Moonlight can also be used in seawater environments, such as yachts, without corroding or oxidizing. Two times a year, the mold’s surface is restored, resulting in a shiny, completely even light surface.

First and Foremost, Quality

With the exception of the lamp socket and wiring, all Moonlight parts are roto-moulded PE and PC. As a result, the company is able to control the thickness, which results in both outstanding light quality and UV stability. Furthermore, Moonlight lamps are extremely stable and robust against stresses and impacts. Rotomoulded lamps are particularly resistant to UV rays and temperatures from -40 to +80 degrees Celsius.

> Moonlight Battery Light

> Moonlight Lamp Full Sphere with Flexible Base

Partnering in a Special Way

Over the years, Moonlight and Matrix Polymers have collaborated not only in supplying high quality raw materials but also in finding the best production solutions to produce high performance rotomoulded lamps. To continually improve the production process and the final quality of the lamp object, Matrix Polymers deploys its expertise in the rotational moulding.

> Moonlight with screw-on base

> Moonlight lights stone look

Illuminate Multiple Environments

Moonlight lamps are highly versatile products that can be used for a wide range of applications. They are actually luminous globes that can be placed on the ground or suspended from a power cable. Furthermore, they can be used inside homes as well as for furnishing public spaces such as stations, airports, event spaces, exhibition halls, etc.

03 Frontier Polymers Contemporary Design

A pioneer in rotational molding, Frontier Polymers has created Sereno, a brand specializing in contemporary design objects.

Objects that enrich daily lives, remove boundaries between indoors and outdoors, objects that we feel at one with. As well as being aesthetically pleasing, Sereno’s eye-catching designs are highly functional, and demonstrate their mastery of new synthetic polymers and moulding processes.

Therefore, these high-quality weather-resistant designs allow a natural and almost seamless transition from indoor to outdoor spaces, thereby considerably extending living areas. With a clean design philosophy, Sereno products are functional, aesthetic, innovative, and practical. Through its product line, Sereno offers a variety of opportunities to experience nature and light. Ways that invite us to pause, relax, sit, breathe, and enjoy the moment.

An emerging company investing in quality design and products must consider the quality of the materials used. Aside from offering innovative materials, Matrix Polymers assists manufacturers in their growth and evolution.

> Sereno’s eye-catching designs

Innovate Products in Depth

Rotomolded products from Frontier Polymers represent innovative objects from different perspectives. In contrast to existing products on the market, their design makes them highly recognizable. Products capable of characterizing environments with elegance and personality. Additionally, they combine valuable aesthetic quality with useful functional quality to solve daily needs. However, their innovative capability extends beyond formal and functional quality to include also the quality of polymeric materials at the core of the rotational molding.process.

> Product features

Quality Polymers for Best Performance

Materials from Matrix Polymers are used by Frontier Polymers to optimize the manufacturing process and produce high-quality mass-produced products. For this reason, the polymers used in Sereno collections must provide maximum performance and resistance to different environmental conditions, both inside and outside the home. It is necessary to use polymers that enhance the external surface and provide strength and durability over time.

UV Resistant Products

Sereno products are characterized by their ability to be used both indoors and outdoors, i.e. by their flexibility of use. Matrix Polymers supplies UV-stabilized polyethylene, ideal for producing rotomoulded objects for any environment. As a result, they are protected from the sun’s harmful ultraviolet rays, which can fade other products over time. We are able to offer long-lasting products due to the use of these polymers.

> Grande Large Planter

Impact Resistant Products

Plant pots manufactured by Frontier Polymers are made from engineered polymer resin that resists breakage. Rotational moulding of the pots is done with quality polymers that provide a strategic advantage over traditional materials like ceramic and terracotta as well as non-high quality plastic pots. Impacts tend to damage the latter and cause them to crack easily.

The Value of Light

Illuminate the Environment Evenly

With Matrix Polymers materials, products can be rotomoulded, ensuring a homogeneous distribution of artificial light. As a result, light diffusers of different shapes and sizes can be designed to provide constant lighting in a specific surrounding area, whether they are floor, table, wall, or suspension lamps.

On the one hand, rotomoulded products for interiors and exteriors offer an aesthetic quality during the day related to sunlight. However, they are enhanced in the evening when the lighting is integrated into the rotomolded body. This dual appearance of the rotomolded product presents a captivating image that must be accompanied by the use of quality polymers, such as those produced by Matrix and used in the Sereno collection of lamps.

> Esagono Floor Lamp

> Triangolo Table Lamp

Enhance the Surface

Vases, lamps and furnishing elements in the Sereno collection are characterized by three-dimensional surfaces where volumes and textures give a sophisticated and complex image to the products. Through the play of shadows and lights produced by the internal lighting, the surface texture of the rotomoulded object acquires strength and depth. They are as beautiful to the touch as they are to the eye due to the tactile perception they generate.

> Detail of the Surface

Quality of Lightness

Rotomolding hollow bodies using quality polymers reduces the thickness of the walls to a minimum while ensuring the necessary strength. You can obtain large and mediumsized products with a reduced weight, making them easier to move and transport.

> Chiara Large LED Planter

APEX Group Green Hydrogen Systems

APEX Group, founded in 2000 in Rostock/Laage, Germany, has been one of the pioneers in the hydrogen industry since 2012. It is the company’s primary objective to become an internationally recognized developer and operator of hydrogen plants.

APEX’s core business is developing, constructing, selling, or operating green hydrogen electrolysis plants with a capacity of up to 1 GW. The development of these cuttingedge facilities is vital to the decarbonization of industrial value chains as well as to the production of green hydrogen and hydrogen derivatives like chemical hydrogen carriers and e-fuels. The solutions are applied to energy-intensive industries such as steel, chemicals, and cement, contributing significantly to their sustainability efforts.

In addition, APEX provides hydrogen infrastructure and logistics solutions, particularly in international industrial settings such as warehouses, ports, and production facilities.

To create a more efficient and sustainable society, renewable energy storage represents a crucial challenge. In order to address this important issue, APEX has developed an innovative industrial approach.

Innovative Storage Solutions

Renewable energy’s inherent nature is unpredictable. It fluctuates based on environmental conditions and may not align with peak demand on the electrical grid. Innovative technologies like electrolysers have emerged, allowing us to store energy in the form of Hydrogen gas for later use. Recognizing this potential, APEX has identified storage solutions as a pivotal product group that will play a crucial role in shaping renewable energy’s future. To this end, they have established a dedicated subsidiary, HydroExceed, specialising in the production of hydrogen pressure storage vessels.

> New 100 MW Electrolysis Plant, Rostock/Laage > CO2 Neutral Industrial Park, Rostock/Laage

Bridging the Energy Gap

Through the provision of efficient and reliable storage solutions, APEX strives to bridge the gap between renewable energy generation and its demand, ensuring a reliable and sustainable supply of power for a variety of applications.

A focus on storage technologies positions them as a key player in driving the clean energy transition, and fostering a greener future, for future generations as the adoption of renewable energy sources continues to grow.

Achieve Carbon Neutrality

APEX Group is a pioneer in the green energy transition. On behalf of their customers, they develop solutions for a CO 2 -neutral energy supply on an industrial scale. Their business model is based on project development and storage solutions. APEX assumes the role of an EPC partner for their clients, overseeing everything from approvals and detailed planning to the installation and commissioning of turnkey H2 projects. Beyond this, APEX has their own H2 production facility and operates a H2 power plant, complemented by an H2 refuelling station and an H2 trailer filling station.

Rotomoulding as Key Solution

APEX / HydroExceed utilizes crosslinked polyethylene for the rotomoulding of their liners, a material that has consistently demonstrated an exceptional balance between ease of processing and permeation performance. This material choice ensures that their customers receive top-notch liners that fulfil their requirements while also offering a costeffi cient solution. Rotomoulding allows HydroExceed to achieve exceptionally stable liner geometry, completely free from the surface defects often encountered in other productions.

> CO2 Neutral Industrial Park, Rostock/Laage

> CO2 Neutral Steel Production

> Type IV Pressure Vessel: Single Tank, Up To 500 bar

An Alliance to Innovate

Seamless Liners

APEX has a long standing partnership with Matrix Polymers that began while developing their inaugural product - the TYPE IV vessel for stationary hydrogen storage. As APEX sought the optimal materials to align with their objectives, the collaboration with Matrix Polymers proved invaluable. Through a series of rigorous tests and design refibements, Matrix Polymers’ expertise and profound knowledge were crucial. Their contributions culminated in a certified product that APEX was able to proudly present to the market.

One of the most significant benefits is the ability of rotational moulding to create liners with seamless construction. Unlike other technologies that rely on joining pieces, this technology forms a single, homogeneous liner. It eliminates weak points that seams and welds can introduce, especially under fluctuating loads introduced by repetitive filling and emptying of hydrogen storage used in transport. By adopting rotational moulding, HydroExceed ensures that their liners possess a level of structural integrity and reliability that surpasses other manufacturing methods.

> Type IV Pressure Vessel

Experience and Knowledge

As APEX / HydroExceed ventured into new product territories, the need arose for a seasoned partner skilled in a vast array of polymer products, processing, and technologies. The objective was to develop a reliable hydrogen storage product to meet market demands. Matrix Polymers’ continuous support has been invaluable, particularly in determining the optimal processing parameters for liner production and ensuring the best synergy between various polymer and non-polymer materials.

> Type IV Pressure Vessel: Single Tank, Up To 500 bar

> Rotational Moulding Process

Main Benefits

With the expertise of Matrix Polymers’ specialists playing a pivotal role in the development of APEX’s new products, a superior quality was achieved. Furthermore, through this continuous exchange of information and knowledge, APEX has obtained the possibility of creating products that optimize their manufacturability on an industrial level.

Floteks Automotive Industry

Floteks was founded in 1978 to apply flocking to plastic parts. In 1983, Floteks became the first company in Turkey to manufacture plastic parts using rotational molding. In today’s marketplace, Floteks is a pioneer in rotational molding and has international recognition. Through license agreements, Floteks exports technology to foreign companies.

Floteks is competent in product design, product development, engineering analysis, material and product testing for commercial vehicles, tractors and construction machines. As a fully integrated plant, Floteks designs and manufactures products, manufactures molds, prepares powder, manufactures rotational molded parts, assembles, tests, and controls quality. Floteks offers a wide range of products for the automotive industry. Amongst our main product groups are diesel fuel tanks, AdBlue (Urea) tanks, expansion tanks, fenders, bus cabinets, air ducts, tractor ceilings, interior trim parts, wiper water tanks, and hydraulic oil tanks. Under the Subterra brand, Floteks produces innovative products for the agriculture, livestock, and food sectors.

The case of Floteks exemplifies our approach: from large companies to small ones. In order to create innovation, every customer is important and becomes a strategic partner. Regardless of size, production capacity, or turnover.

A New Industrial Challenge

An emblematic case that distinguishes the research and innovation developed by Floteks is related to Daimler buses. The German company was looking for an alternative technology for their storage boxes for their buses. Daimler was interested in making these products lighter and cheaper and for this reason rotational molding appeared as an interesting solution for which, however, the company had limited experience having produced, until then, only a rotomolded waste container.

> Detail of the opening mechanism

> Daimler Bus - Storage Box

Conception to Completion

When Daimler contacted Floteks, the project was still at a very general level and initially focused on the use of other production technologies. By using a single wall design for the main body and a double wall design for the lid, Floteks was able to meet most of their requirements, reducing the number of parts, assembly time, part weight, and overall cost. It was determined that rotational molding was the most appropriate technology to meet the client’s performance requirements for the entire project.

Quality in the Details

Rotomoulded parts had to integrate with the designers’ aesthetic vision. As a result, several suggestions to reduce waste and simplify production have not been accepted. In addition, even from a chromatic perspective, the rotomoulded pieces had to be coordinated with the interior of the bus. The process proved to be more challenging as different components produced using different technologies had to coexist. Furthermore, the lid hinges had to withstand thousands of openings and closings.

> Rotomoulded parts for MAN

> Rotomolded parts for MAN

The Value of Research

A long process of research led to the development of the rotomolded container. Many details also contributed to the visual appearance of the final product: the seams were positioned so as not to be directly visible to people, while the final colors had to coordinate with those inside the vehicle. In this work, Matrix Polymers played a key role both in selecting the most appropriate material and in determining the additive polymer’s flammability and colorability.

Warrior Industries Water and Septic Tanks

Warrior Industries was founded in 2013, with its manufacturing facility located in Lae, Papua New Guinea. Over the past decade, the company has established itself as the largest supplier of water and septic tanks in PNG, a country located in the South Pacific. Warrior Industries is the only company to hold both the AS1170.0 Earth Quake Rating certification as well as the AS/NZS 4766 certification.

With the aim of providing the market with reliable tanks that are highly resistant, Warrior Industries has invested in the quality of its products since its inception. In order to meet the needs of liquid transport and containment, the company has developed an extensive range of products using rotational technology.

It is Matrix Polymers’ role in certain geographical areas, such as the South Pacific, to contribute to the creation of quality products that significantly improve people’s lives.

> WAR-N-WT3500 Tank

Useful and Functional Products

There was a clear need for a manufacturer that would provide products for micromanagement of water and sanitation with a strong culture of continuous improvement. Dedicated to becoming PNG champions in Water, Sanitation, and Hygiene, Warrior Industries partnered with an Australian company Ecoflo. Rotomoulding their wellestablished Clivus Multrum™ range of dry toilets. It provides an excellent option for sustainable waste management and sanitation. These are all rotomoulded products aimed at improving health outcomes and quality of life.

Enhancing the Quality of Life

People’s health, quality of life, and economic development are adversely affected by the environmental conditions in South Pacific cities and villages. When basic urban and rural services, including water supply and sanitation, are improved, public health and general social indicators are improved. Most urban and rural poor resort to informal methods for disposing of human waste, contributing to the high incidence of intestinal diseases that are endemic in most major cities.

> Nestable Round Tanks

The Right Material

Collaboration between Warrior Industries and Matrix Polymers has resulted in the development of tanks and containers that are known for their outstanding reliability, resistance, and durability. By using Revolve® 6329U, a polymer characterized by impact strength, stiffness, and flow characteristics, this has been possible. As a result, the material is able to withstand external forces and impacts without compromising its structural integrity. The high stiffness ensures the tanks retain their shape and do not deform under load.

> Tank collection

> 3000L Slimline Water Tank

F-SERIES

The NEW range of Non-nestable Tanks includes 3 different Sizes: 1000, 3000 & 5000 litres. Partnerships that Work

As a result of this collaboration, a variety of innovative and high-performance products have been developed to meet the needs of various industries. Due to their indepth knowledge of polymer science and expertise, both companies have been able to develop customized solutions that excel in their respective applications. Together, the collaboration has been able to identify the most suitable polymer for each specific performance requirement. As a result, products that offer superior durability, strength, and chemical resistance have been developed.

> Promotional Campaign by Warrior Industries

Preserve the Water Ecosystems

In recent years, new designs have led to the development of innovative water tanks that can be easily transported and installed in a variety of environments. In the area of clean water and sanitation, this represents an important step towards achieving the Sustainable Development Goals of the United Nations. The provision of clean water through these tanks contributes to the preservation of water ecosystems and their biodiversity. Additionally, they can contribute to efforts to combat climate change by promoting water conservation and efficient water use.

Clean Water as a Key Resource

Papua New Guinea’s climate is influenced by the northwest and southeast monsoon circulations. Throughout the year, these monsoons bring rainfall to many areas, resulting in a wet climate. There is a seasonal shortage of water in both urban and rural areas. In Papua New Guinea, a significant portion of the population lacks access to safe drinking water. The majority of Papua New Guineans lack access to clean water, forcing them to purchase it from street vendors at a high price.

> Promotional Campaign by Warrior Industries

WATER QUALITY.

The following are all registered trademarks of Matrix Polymers.

Super-Linear® Designed for Roto®

Revolve®

The information contained in this magazine is given in good faith. The suitability for the application and performance of goods manufactured with materials processed and/or sold by Matrix Polymers is the sole responsibility of the end user. Product design, the production process and parameters of end use are factors that may affect the performance of the finished product and these and other factors are outside of Matrix Polymers’ area of control.

Matrix Polymers Ltd. Registered in England and Wales company number 02626784.

Registered office: The Priory, Orchard Hill, Little Billing, Northampton, NN3 9AG, UK