Expanding Horizons Issue 3

Expanding Horizons

Unlocking the Potential of Rotational Moulding Edition 3 u Image co

f rtesy o

Dena

do mora

Index 01 Introduction

02 Case Studies

03 Summary

From the Editor

Martin Coles

01

Matrix Polymers Launch of EcoMould Matrix Polymers

02

From Idea to Final Product

Euro3plast

09

The Evolution of Roto Technology

Persico

13

Quality First

Rotovia

18

The Value of Research Queen’s University Belfast

23

Credits

28

Contact Us

29

Martin Coles, Group CEO

From the Editor Welcome to Expanding Horizons, a magazine we introduced two years ago to celebrate the dynamic partnerships we’ve fostered with our manufacturing collaborators. Our mission is to explore and share the intricate stories from various industries and regions, highlighting the complex, challenging, and rewarding experiences our customers face. Through detailed case studies, we shine a light on the vital role Matrix Polymers plays within the rotational moulding value chain.

This year’s edition centers on sustainability, broadening our perspective to include insights from experts across various fields. At Matrix Polymers, we aim to serve as a platform for diverse voices, all driven by a shared commitment to advancing the boundaries of their disciplines.

Our target audience extends beyond moulders—we aim to engage brand owners, OEMs, and end users who may not yet fully appreciate the unique benefits and innovations of the rotomoulding process.

Reaching a global audience of OEMs and rotomoulders, we have the opportunity to drive and inspire innovation throughout the industry.

Enjoy the read!

01

01

01 Embracing Sustainability in Rotational Moulding

Matrix Polymers Approach to Material Innovation Matrix Polymers has ramped up its R&D to develop sustainable materials, recognizing that sustainability is now a core industry imperative, not a luxury. In rotational moulding, factors contributing towards sustainability can be advanced by selecting materials that reduce cycle time and energy use, cutting virgin material consumption through downgauging, using bioderived materials to lower carbon footprints, lightweighting with foaming, and integrating recycled materials—addressing various environmental and social challenges along the way.

Rising Demand and Regulation Drive Recycled Content in Plastics Industry Recycling has become a major focus in the plastics industry, with the UK’s 2022 plastic packaging tax charging £210.82 per tonne on packaging containing less than 30% recycled content. Originally targeting singleuse items, these requirements have expanded due to rising consumer and corporate demand for sustainability, now encompassing more durable goods and longer serving goods. Further, the European Parliament has proposed regulations requiring automotive products to include at least 25% recycled plastic, partially sourced from end-oflife vehicles, underscoring the industry’s shift toward recycled content in long-lasting applications.

02

Engineering Sustainable Solutions The drive to use recycled materials, especially postconsumer recycled (PCR) options, is encouraging engineers to reduce reliance on virgin materials.

Rotational moulding is particularly suited for durable goods which can achieve and extend product life spans up to 20 years, this is a significant opportunity to increase value of recycled material through the Roto process.

However, challenges like thermal degradation, differences in polymer structure, material chemistry, and limited supply chain stability hinder exclusive reliance on PCR materials from other polymer process methods.

Although there are many successful schemes globally to use recycled rotationally moulded products, which have good material hetaeristic we cannot relay on this alone.

Matrix Polymers addresses these issues by engineering PCR-based materials specifically tailored to rotational moulding, advancing sustainable options for long-lasting applications.

03

Balancing Sustainability and Performance A major challenge in using PCR materials for rotational moulding is achieving the right viscosity and thermal stability.

Material characteristics essential for effective sintering can be challenging to achieve if the materials were not originally designed for the rotational moulding process.

In recent studies at Matrix Polymers we have identified, adding 30% PCR results in a 50% drop in impact strength.

This highlights the need for continuous innovation to balance sustainability with performance.

As the industry evolves, Matrix Polymers remains committed to

refining

these

solutions,

ensuring

that

rotational

moulding contributes to a sustainable future through thoughtful material choices and advanced manufacturing techniques.

04

Expanding the Potential of Recycled Materials – Matrix Polymers Launch of EcoMould Matrix Polymers is leading the way in sustainable material solutions with sustainability now an industry essential, the company has introduced EcoMould—a brand offering materials that marry performance and recycled content.

Designed to align with key specifications for generalpurpose applications, EcoMould is “roto-friendly” and suited for diverse uses, from flower pots, container cases, and furniture to industrial machinery.

Although the properties are similar to virgin materials, there are still some unanswered questions, those related to long-term performance in particular. We have partnered with third-party labs, to explore tests relating to creep and environmental cracking, key requirements of our industry to meet long-term performance needs.

Amid evolving sustainability requirements, Matrix Polymers remains aligned with industry standards and regulatory changes, ensuring that EcoMould and future innovations meet compliance. With a focus on sustainable impact and functionality, Matrix Polymers is poised to drive rotational moulding toward a greener future.

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EcoMould N-3010R PRO

MFI: 3.5

Post Consumer Recycled Grade

Description

Density: 0.936

Physical Properties

EcoMould N-3010R PRO is PCR based rotational moulding polyethlyene (PE) grade. Post-consumer recycled (PCR) PE is made from recovered materials that have already been used by consumers, specifically food and drink bottles. The recycled content of this grade is a minimum of 30% in weight.

Features & Benefits Medium Stiffness

Available as:

• Good mouldability

• Natural pellets & powder

• Good impact strength

• Black pellets & powder • Coloured powder

Properties

Test Method

Value

Unit

MFI

ISO 1133

3.5

g/10min

Density

ISO 1183

0.936

g/cm3

Tensile strength @ Yield (50mm/min)

ISO 527

16

MPa

Flexural Modulus (1.3mm/min)

ISO 178

690

MPa

Elongation Break @ (10mm/min)

ISO 527

85

%

HDT at 0.45 MPA

ISO 75-2

55

°C

ARM-I Standard

60

J

ARM Impact (-40°C, 3mm thickness )

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Leading the Way in Sustainable Manufacturing Practices with our PCR Material Grades At Matrix Polymers, we have developed several high-quality PCR (Post-Consumer Recycled) material grades. These innovative solutions reflect our dedication to environmental responsibility and sustainability within the plastics industry.

Now is the time to make a difference. Join us by incorporating PCR materials into your manufacturing processes, reducing your environmental footprint, and contributing to a more sustainable future.

To learn more about our products and material solutions get in touch at:

sales@matrixpolymers.com www.matrixpolymers.com

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03 11

08

02

From Idea to Final Product

Euro3plast Founded in 1974, Euro3plast began by producing plastic products for gardens and homes. Innovation in the design of pots, home accessories, and lamps has driven the company’s ongoing growth, enabling it to distribute products globally.

In 2023, Euro3plast took a significant step by releasing its first Sustainability Report, aimed at transparently evaluating and sharing its progress and future commitments to sustainable development.

Plust

is

the

design

brand

created within

Euro3plast.

Through partnerships with international designers and a commitment to continuous research into finishes and highquality polymers, Plust has developed an extensive range of furniture and decor accessories. This innovative product line seamlessly blends form and function, showcasing the limitless possibilities of rotational moulding.

There can be no innovation without a good idea.

But even a good idea must be supported by a good polymer to become reality. These basic principles form the benchmarks that guide the company in the development of new quality products.

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Reliable Outdoor Products The Euro3plast and Plust collections are distinguished by the versatility of their products. These items are designed for flexible use in outdoor settings, whether in public spaces or private areas. For this reason, one of the company’s primary challenges was ensuring resistance to environmental elements, particularly sunlight and surface dirt caused by prolonged outdoor exposure.

> Fade, table lamp, production Plust

> Fade Shell, divider, production Plust

The Right Polymer for Every Need The collaboration between Matrix Polymers and Euro3plast is very important to define a range of polymers that would guarantee high outdoor performance and durability.

The Linear Low-Density Polyethylene (LLDPE) that is used for rotomoulding products guarantees excellent surface resistance and resistance to the stresses to which a product may be subjected outdoors. In addition, the masterbatch used guarantees to high UV resistance and maintains its mass colouring over time.

14 10

Achieve More with Less Minimizing surface tensions during rotational moulding is a key challenge in making the production process more efficient and energy-saving. With Revolve® by Matrix Polymers, rotational moulding times are shortened, significantly reducing the gas consumption required for the entire cycle. Achieve more with less: this principle is central to creating innovative products that align with environmental sustainability.

> Gumball, sofa, production Plust

> Gumball collection, sofa, armchair, pouf, production Plust

Expand Beyond Boundaries Every new Euro3plast and Plust product is created through a well-defined process, beginning with the designer’s creative input and followed by careful analysis and refinement of the rotomolded item. Collaboration between professionals with diverse expertise is essential to achieving a high-quality outcome. Selecting the right polymer to meet specific performance requirements is a key part of this process, helping to address particular needs effectively.

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Longevity as a Core Value Euro3plast’s products are grounded in a clear mission: to endure over time by withstanding the physical and mechanical stresses they encounter. In this context, Revolve® N-1010 is a polymer that offers an exceptional balance of properties, including outstanding impact resistance, a broad processing window, and excellent printability. With the incorporation of this polymer, the company’s rotomolded products exhibit high stress resistance and maintain their quality over time. These products are designed for longevity, challenging the notion of disposability.

> Fade Stack, chair, production Plust

> Rebelot, pot, production Plust

New Opportunities for Technology For Euro3plast, the near future of rotational moulding is brimming with opportunities. The technology’s flexibility allows for the gradual expansion of applications across various sectors. In this regard, the availability of a diverse range of polymers enables the development of tailored solutions to meet specific functional needs. Rotational moulding has the potential to transform the aesthetics of many industrial products through the optimal combination of design, materials, and technology.

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03

The Evolution of Rotational Technology

Persico Persico Group is committed to leading the industry by seamlessly integrating innovation and technology with its tools and machinery offerings. By harnessing cutting-edge advancements, the company creates synergies that not only elevate the performance of its products but also redefine the possibilities of what technology can achieve. Capitalizing on its technological leadership in research, development and experimentation, Persico supplies advanced tools and equipment to industry-leading customers.

The Rotomoulding Division represents one of the main sectors of Persico Group. The great experience gained in the production of molds and automated machines for rotational molding allows Persico to offer a quality service in the design, development and production of rotomoulded industrial objects.

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Persico is an international leader in applying the latest technologies and manufacturing techniques to give its customers the edge in high quality tooling and world beating machinery.

Direct Tool Heating SMART® Rotomoulding technology, introduced by Persico in 2013, has revolutionized the manufacturing of composite products. The development of DTH (Direct Tool Heating) machines and tools enables the production of a wide range of items with remarkable efficiency and precision.

SMART® technology is designed as a compact, clean, and safe production cell that optimizes energy and material usage.

> SMART rotomoulding machine

> > SMART rotomoulding line

Producing More with Less Energy The fully automated process integrates one or more machines with anthropomorphic robots, enabling seamless operations that include powder loading, insert loading, release agent spraying, automated moulding cycles, and product discharge. This results in high production rates, significant cost savings, reduced labour requirements, and a rapid return on investment. With its minimal footprint and use of electric heating instead of gas, SMART® technology guarantees high productivity.

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Enhancing the Potential of Polymers SMART® Rotomoulding technology offers a number of advantages to enhance polymer performance. By using the internal atmosphere control system, products can be rotomoulded to fully exploit the properties of the polymers, resulting in longer-lasting and more capable solutions for complex functions. In addition, DTH (Direct Tool Heating) technology reduces the polymer oxidation process with an inert internal nitrogen atmosphere, helping to ensure better performance of the rotomoulded part.

> SMART rotomoulding machine

> Direct Tool Heating

Wide Variety of Polymers for Every Need SMART® technology enables consistent product quality through

optimal

processing

and

thickness

control.

This also leads to a reduction in product deformation and allows the use of a wide range of polymers in addition to PE, such as PA6 (both liquid and powder), XLPE, Polypropylene, EVA, PLA, Nylon (both liquid and powder),

Polycarbonate,

Water-soluble

15

polymers,

PEEK, PVA

Polystyrene, ABS,

Polyester,

EVOH,

PVDF.

Smaller Footprint for High Performance SMART is a compact moulding production cell providing a clean, safe production environment. The working volume (BUBBLE) of SMART machine is 2.8 m diameter with a depth of 1.8 m. Smart makes it possible to mount a single large and complex mould or multiple smaller moulds on the Machine for each cycle, heated by numerous independent circuits. Thanks to this type of machine it is possible to rotomould products of various sizes while fully exploiting the performance of the polymers used.

> SMART rotomoulding machine

> Loading the polymer into the mould

Hollow Seamless Liners Having been asked over recent years by customers to provide production systems for manufacturing liners for H2 and CNG tanks, a specific new generation machine has been developed. This SMART H2 machine provides state of the art production of hollow seamless liners in a variety of polymers using highly developed rotomoulding technology. Persico can provide design assitance, full product development, toolmaking, prototyping and pre production.

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17 03 11

04

Quality First

Rotovia Rotovia is an international rotomoulding company with a 50+ year history as a leader in the plastic manufacturing industry. With a rich heritage and a wealth of experience, the company has produced high-quality, innovative and durable rotomoulded products for decades. Our expertise in rotomoulding technology has enabled us to offer an extensive range of custom and proprietary products catering to a variety of industries and applications. The company is committed to innovation and sustainability, always striving to produce better products while reducing its impact on the environment.

With eleven (11) production facilities worldwide, Rotovia is truly an international organization. Our custom moulding business unit operates in various market segments, including renewable

energy,

agriculture,

leisure,

construction,

building, and vehicles. Similarly, our proprietary products division serves Europe and the Americas, producing tubs for industries such as fish and seafood, pork, poultry, beef, by-products, and pet food. At Rotovia, our goal is to deliver creative, differentiated solutions that consistently exceed our customers’ expectations.

For a company that has based its development on sustainability, it is essential to use quality polymers that are capable of turning the demands of energy efficiency and high performance into reality.

18 13

A Name, A Mission Formed in June 2022, Rotovia became an independent company, charting their own course towards the future.

The name Rotovia, reflects its vision by combining “Roto,” representing the rotational moulding process and commitment to circularity, with “Via,” the Latin word for road, symbolizing the path toward sustainability. Our goal is to drive growth both organically and through selective acquisitions, building on our strong legacy to expand our reach and capabilities.

> Rotomoulding plant

Developing Sustainable Solutions At the core of Rotovia’s mission is empowering customers with premium, sustainable solutions. We position ourselves at the higher end of the market, with a focus on quality and environmental responsibility. Our focus is on product weight reduction and extended product life to improve customer efficiency and effectiveness with the reducion of operating costs. We assist clients achieve sustainability and their broader ESG goals by integrating recycled materials into their designs, fostering eco-friendly innovation.

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> Mould rotation on the arm

Growth with Environmental Responsibility The

Rotovia

sustainability

journey

began

with

the

establishment of Strategy 2028, shortly after Rotovia’s formation. Over 20 projects were initiated, with a strong emphasis on sustainability improvements. For Rotovia, sustainability means delivering on present needs without compromising the environment for future generations.

> Polymer for rotational moulding

> Mixing polymers

Transforming Waste into a Resource One of our key initiatives is to increase the recycled content in our products to 20% by 2028. In 2023, 2.9% of our raw materials were sourced from post-consumer recycled (PCR) content, and we are committed to raising this figure to 8% by 2025 and 20% by 2028. Achieving this target requires transitioning from a linear production model to a circular one, where products are reused, repaired, and recycled at the end of their life cycle. Rotovia is making significant strides in this direction; for example, our proprietary VARIBOX containers now consist of 30% PCR material.

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Two Key Cases Rotovia aims to take back 30% of its products for reuse or recycling within the next five years. Our strong proprietary brands—Sæplast, iTub, and Varibox—are at the forefront of promoting reusability and circularity. Sæplast is renowned for its rotomoulded triple-wall food containers, primarily used in the fish, seafood, and meat industries. These containers are designed to be reusable, repairable, and recyclable.

Similarly, Varibox offers industrial bulk containers (IBCs) for the chemical market. These innovative containers feature a unique traceability system and a design focused on safety.

> Rotomoulding plant

Create More with Less Energy Our initiatives also focus on reducing our carbon footprint.

Currently, our production equipment generates around 10,000 tonnes of CO2 annually. To address this, Rotovia is enhancing energy efficiency and transitioning to greener energy sources as part of our decarbonization efforts.

In Iceland, we have successfully operated an electric rotomoulding carousel machine powered by green energy for over a decade. Recently, we retrofitted a second machine with a new electric oven, further advancing our commitment to sustainable production.

21

> Varibox chemical containers

03 11

22 34

05

The Value of Research

Queen’s University Belfast Queen’s University Belfast has been at the forefront of research into Rotational Moulding for over 30 years, and it continues to work with the industry on a wide range of technological innovations. Sustainability has been at the heart of much of its work from the development of the groundbreaking ‘Rotolog’ device in the late 1980s through the latest efforts to automate and add intelligence to the process.

Research into polymer materials has included efforts to understand and control the basic melting and sintering process that is fundamental to making the rotational moulding process more sustainable.

Research in the world of rotational moulding is key to evolving the technology by increasing performance and reducing limits and bottlenecks.

The role of Queen’s University Belfast is strategic in driving rotational technology towards increasing levels of quality.

23

The Qualities of Recycled Plastic Rotational moulding has been seen as a potential route for capturing some forms of plastics waste due to the relatively large size and longevity of many of its products. However, controlling the loss of impact strength and product colour are significant challenges. Blending, layering and foaming have all been shown to give positive results. In addition, innovative work on architectural blocks has demonstrated that rotational moulding can be used to create recycled products that are tactile and aesthetically pleasing.

Increasingly Automated Technology Automation is already bringing transformational change to rotational moulding through several new automated moulding platforms.

Amongst these is the ‘Robomould’

system developed by AMS Robotics in Belgium, where a robot arm provides multi-axial movement of an electrically heated tool. In terms of sustainability the use of automated movement and electrical heating provide a quantum leap in the levels of energy efficiency and control. Furthermore, the removal of the oven is providing an open environment for researchers to exploit for the first time.

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Sensors and Instrumentation With an improving diversity of computer software, and the rising capacity of computer hardware, computer modelling is increasingly being used as a research tool in rotational moulding. Some of the latest advances are in thermal models to assist in the design of electrically heated tools, models to predict powder movement and part wall thickness distribution, and simulations of part shrinkage and warpage. Modelling is also being used extensively in the design, analysis and performance testing of mould tools and final products.

Hydrogen Liners With increasing process control and efficiency, new high technology applications are emerging for rotational moulding.

One of these is in the manufacture of polymer liners for type IV hydrogen storage vessels. Here the process offers significant advantages in its production flexibility and its ability to ensure encapsulation of the polymer with metal components such as bosses and tailstocks. It also provides the advantages of multishot moulding that can add internal gas barrier layers that are essential for longer term hydrogen storage.

25

Sustainable Materials Recyclate adoption in rotational moulding, especially post consumer recyclate (PCR), poses significant challenges.

Collaboration with Matrix Polymers aims to address some of these. This research extends towards natural fibres and challenges, improve performance and mechanical properties of recycled materials for rotational moulding. To date this project has focused heavily on blending of recycled materials, modification of recyclate and investigating thermal stability. Furthermore, novel biopolymers and natural fillers which has complimented industrial trials at CP Cases.

Recyclable Biopolymers CP Cases, a leader in protective cases and containers, has partnered with Matrix Polymer and Queen’s University to pioneer sustainability in the rotational moulding industry.

Funded by Innovate UK, this project developed and integrated recyclable biopolymers into manufacturing processes, significantly reducing environmental impact.

A range of biopolymers were successfully assessed and characterised before industrial scale rotational moulding trials.

26

27 03

Credits > Photo credits Ravi Kant Cover Eva Bronzini

Pg 01

EcoBirdy Pg 08 Matrix Polymers 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

Pg 09

Euro3plast Pg 10-12 Persico Pg 14-17 Rotovia Pg 19-22 Queen’s University

Pg 24-27

> Editorial contributions Aldo Quaratino, Group Technical Director Ranbir Kooner, Group Brand Marketing Manager

the finished product and these and other factors are outside of Matrix Polymers’ area of control.

Jake Kelly-Walley, R&D Engineer, Matrix Polymers > Concept and Graphic Design Studio Giovanetti

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

Registered office: Unit 2 Compass Industrial Park, Spindus Road, Speke, Liverpool, L24 1YA UK

> All rights reserved by Matrix Polymers. Partial or total reproduction of the contents is prohibited without the prior authorization of the company

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Get in touch

Registered Office Matrix Polymers Liverpool Unit 2, Compass Industrial Park, Spindus Rd, Speke, Liverpool, L24 1YA, UK Tel: +44 (0) 151 448 7000 Email: sales@matrixpolymers.com Matrix Polymers Polska Sp. z o.o.

Ul. Torunska 239/241 62 600, Kolo, Poland Tel: +48 63 888 1069 Email: sales@matrixpolymers.com

Matrix Polymers Thai Co.,Ltd. No. 13, Highway No. 3191 Road, Tambol Huai Pong, Amphur Mueang Rayong, Rayong Province 21150 Thailand Tel: +66 3368 3393-4 Email: sales.th@matrixpolymers.com Revolve Matrix Polymers Malaysia Blok A, Lot 766, Persiaran Selangor, Seksyen 16, 40200 Shah Alam, Selangor Tel: +603 5524 5181 Email: sales.my@matrixpolymers.com

Global Footprint

Six Manufacturing Sites Across Three Continents Production / Manufacturing Technical Services Warehousing

APAC R&D European R&D

www.matrixpolymers.com

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Matrix Polymers Australia Pty Ltd 37 Antimony St, Carole Park, QLD 4300 Australia Tel: +61 (0) 7 3718 5400 Email: sales.aus@matrixpolymers.com Matrix Polymers New Zealand 39 Railway Road, PO Box 5078, Terrace End, Palmerston North 4441, New Zealand Tel: +64 (0) 6 357 8498 Email: sales.nz@matrixpolymers.com