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14101 Highway 290 West, Bldg. 1600-B Austin, TX 78737 USA




manufacturing & processing


Crossing Barriers with

5th Annual Nordic ARM Conference Highlights What’s Your Dream? 2012 StAR Conference Highlights 2011 ARM Hall of Fame Inductees: Jim Leitz and Daven Claerbout

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H1D 500





Crossing Barriers with Leisa Donlan, ARMA CEO


DEPARTMENTS 6 Editor’s Note 10 Contributors 12 Up Front 27 Energy 34 ARM Report 43 Design Commentary 51 The Cutting Edge 56 ARMA | AISR | ARMSA | BPF | NORDIC | StAR | ARM-CE Update 62 Notes from the Road 65 World Marketplace 66 Advertisers’ Guide


28 5th Annual Nordic ARM Conference Highlights

38 What’s Your Dream? Anders Stone, Stanley Widmer

Susan Gibson, JSJ Productions, Inc. Held in Södertälje, Sweden

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44 2012 StAR Conference Highlights Susan Gibson, JSJ Productions, Inc.

Associates, Inc. The Widmer rotationally molded boat hull.

Rotoworld® • january-february 2012

A big success in Delhi!

52 2011 ARM Hall of Fame Inductees: Jim Leitz and Daven Claerbout Susan Gibson, JSJ Productions, Inc.

The highest honor the ARM bestows.


Selling the Rotational Molding Industry! “The number one goal of our website is to GROW the industry and assist in growing your businesses.”

editor’s note

The beginning of 2012 has started off with a bang. I recently had the honor of traveling to the StAR Conference in India and the Nordic Conference in Sweden. Both conferences were very well attended and a great success! You can read more about the StAR conference on page 44 and the Nordic Conference on Page 28. We have a truly great issue for you inside. Enjoy reading Leisa Donlan’s cover story on a very innovative product with Gough’s Track Pad & Poly Gabion System, it’s exciting for our industry. Also enjoy reading about Stanley Widmer’s life passion that has become reality with his 7 meter boat hull designed for the Navy Special Warfare Center (NSWC). As I stated in my last column of 2011, RotoWorld® magazine has been working on a very innovative website for the industry. The number one goal of our website is to GROW the industry and assist in growing your businesses. We are truly excited about the investment we’ve made and the investment many of you are making in this exciting venture. The website will be rolled out in three phases, the first of which is what we refer to as the foundation, and among its many features, it will include: • Online RotoWorld® Magazine – Each issue will be highlighted on the website as well as some of our most popular

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Rotoworld® • JANUARY-FEBRUARY 2012

articles throughout the years. In addition to highlighting articles in the magazine, we will also have articles specifically for the website. We will offer an industry wide calendar of events as well as hot button issues of the day or week in the worldwide rotational molding industry. • Roto Product Showcase – As many of you know, the manufacturing process is not often “pretty” but we strive to display the beauty that is in the end result of the products that are produced. We hope that through the product showcase; designers, students and end users from around the world will be attracted to the art of making rotationally molded products. • Online RotoTrade™Show – Another piece of the foundation will be the Online RotoTrade™Show. We live in a world that works 24/7 and it never sleeps. RotoWorld will market your businesses 24/7. Currently, we have a readership that spans the worldwide industry, and our largest growing readership sector has been the end user. What a great way to get through the search engine minutia of the Internet today to have your company information on the RotoWorld® website.

the different market sectors as well as associations throughout the industry will also be present on our site. Ultimately, at RotoWorld®, we truly value a medium of communicating the art of what our industry manufactures through the rotomolding process. For years, we have been able to translate this design through print and now we have made a step change to educate and showcase the industry through the web. We hope that you will jump on board and help us grow the industry as well as your business!

Susan Gibson Publisher & Editor

The following phases are staged to be complete in the first half of the year. We will address the need for Social Media in this industry and once you have it, how you maintain it. Each of

Susan D. Gibson

Publisher & Editor President - JSJ Productions, Inc.

Professor Roy Crawford (New Zealand)

Technical Editor Vice Chancellor - Waikato University, New Zealand

Process Editor Paul Nugent (USA/World at Large) MNOP Michael Paloian (USA)

Design Editor President - Integrated Design Systems, Inc.

Global Contributing Editors Dru Laws (USA) Seljan Company Harry Covington (USA)

Ferry Industries

Mark Kearns (Northern Ireland) Gaetano Donizetti (Italy) Robert Dunne (USA) Ravi Mehra (USA/India) Nick Moldan (France & Europe)

Moulding Research Manager

Sales Manager - Persico S.p.A.

President - Meese Orbitron Dunne Co. (MOD) Managing Director - Norstar International LLC

Graphic Sales Agent, Europe - Mold In Graphic Systems®

Clive Robertson (South Africa) Celal Beysel (Turkey)

Chairman - ARMSA

Chairman - Floteks Plastik

Advertising and Art Production Marketing/Advertising Director Jennifer M. Gibson Vice President, JSJ Productions, Inc. Chief Art Director Anya Wilcox

JSJ Productions, Inc.

Circulation & Distribution Administration Regina Rogers JSJ Productions, Inc. Editing & Translations Cheree Hamblen | Tammie Gibson | Ximena Lobo Website & Online Technology Chris Sivori JSJ Productions, Inc. RotoWorld® is a JSJ Productions, Inc. Trade Publication JSJ Productions, Inc. 14101 Highway 290 W. Bldg. 1600-B Austin, Texas 78737; Phone: (512) 894.4106; Fax (512) 858.0486; Email:; and Websites: & Subscriptions One-year subscription (six issues), $60 US, $75 Canada/Mexico, $120 All Other Countries. To subscribe or to submit change of address information, call us at (512) 894.4106; fax us at (512) 858.0486; visit us online at; or email us at You may also write to RotoWorld® Subscriptions, JSJ Productions, Inc., 14010 Highway 290 W. Bldg. 1600-B, Austin, Texas 78737. Advertising For information on advertising, please contact Advertising Director Jennifer M. Gibson, JSJ Productions, Inc, (512) 894.4106. Letters We welcome letters about our contents. Write Letters to the Editor, JSJ Productions, Inc., 14101 Highway 290 W. Bldg. 1600-B, Austin, Fax to (512) 858.0486; or Email Editorial Queries We consider unsolicited contributions. Send manuscript submissions as email attachment to Susan Gibson at JSJ Productions, Inc. bears no responsibility for claim or factual data represented in contributed articles. Postmaster Send changes of address to RotoWorld®, JSJ Productions, Inc., 14101 Highway 290 W. Bldg. 1600-B, Austin, Texas 78737. RotoWorld® is a JSJ Productions, Inc. independently owned, bi-monthly trade magazine for the international rotational molding and plastics design industries. JSJ Productions, Inc. owns all copyrights herein. Reproduction of this magazine, in whole or in part, without the express written ­permission of the publisher is not permitted.

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Rotoworld® • JANUARY-FEBRUARY 2012

Quality and Service with Ingenia’s Superlink® Crosslinkable Rotomolding Resin Ingenia Polymers • 1-800-991-9000 • 416-920-8100 Houston









Roy Crawford

New Zealand Roy is Vice Chancellor of Waikato University, New Zealand, Technical Editor for Rotoworld® magazine and Technical Services Director of the Association of Rotational Molders International. He has published over 200 papers, authored five textbooks on plastics and engineering materials and is the former Director of the Polymer Processing Research Centre (PPRC) at Queen’s University of Belfast. Technical Editor

Ravi Mehra

Paul Nugent

USA/World at Large Paul is a consultant who travels extensively across six continents assisting clients in many roles from training to expert witnessing. He received his Eng. degree in Aeronautical Engineering and Ph.D. in Mechanical Engineering from The Queen’s University of Belfast. Paul developed the Rotolog system, the first complete computer simulation (RotoSim) and authored a book entitled Rotational Molding: A Practical Guide. PROCESS Editor


South Africa Clive Robertson is engaged with cRc Rotoconsult cc, which provides a service to the Rotomoulding industry with regard to Plant Audits, Polymer Sourcing, and Technical Service on special projects. He has 32 years experience in the Plastics industry having been involved with almost every technology sector. He is Chairman of ARMSA and a Fellow of PISA (Plastics Institute of SA).

Robert Dunne

Dru Laws

Michael Paloian


Clive Robertson

USA/India Ravi is Managing Director of Norstar International, the international arm of Norstar Aluminum, located in Princeton, NJ. He is a Past President of ARM International and currently serves on the ARM International Board of Directors as the SARD (South Asia Regional Division) representative.

USA Michael is President of Integrated Design Systems, Inc., Great Neck, New York and Design Editor for RotoWorld® magazine. Over the past 25 years, Mike has developed a broad range of plastic products utilizing various processing methods including rotational molding. Mike’s B.S. degree in Plastics Engineering and Masters in Industrial Design, combined with his extensive experience, has formed the bases for his branded and unique insights into the field of plastics part design.

Leisa Donlan

Australia Leisa Donlan, CEO of ARMA, completed one of only twenty-five fellowships in Australia in 2000 for Non Profit Executives. In conjunction with her ARMA work, Leisa consults to the Queensland State Government on Governance and contributes to the development of ARMO.


Bill Spenceley

Canada Bill Spenceley is the President/Owner of Flexahopper Plastics Ltd. located in Lethbridge, Alberta, Canada. He has been involved in the industry for over 30 years, travels extensively, and currently serves on both the ARM-International and ARMO boards. He has been a frequent presenter on energy reduction in rotational moulding and holds a BSc Chemistry with studies in Chemical Engineering.

USA Robert is President of Meese Orbitron Dunne Co. (MOD). His company, Dunne Plastics, joined MOD in 1993 and became a member of the Tingue companies. Robert is a rotational design and molding expert and tireless advocate for rotational molding education. Bob is also an attorney, CPA and FAA certified pilot.

USA Dru Laws graduated from BYU in Mechanical Engineering and then from QUB in Rotational Molding. Laws has several rotomolding patents and has guest lectured at several universities on the same subject. Dru actively serves within SPE and ARM and has developed award winning products and innovative process improvements in the industry. Dru is currently V.P. of Seljan Company in charge of the Rotomolding Division.


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Anders Stone

Nick Moldan

France & Europe Nick relocated from Brisbane, Australia to Lyon, France with Mold In Graphic Systems®. He is now responsible for MIGS Europe. Nick has been actively involved in the rotational molding industry for 17 years, previously working for Courtenay Polymers in Australia and Polifin in South Africa.

Gaetano Donizetti

Italy Gaetano Donizetti received a Degree in Engineering at the Politecnico in Milan, Italy. His working experience includes designing small automations and production management for international companies. He joined Persico S.p.A. in the Automation Division in 1994, and for the past 2 years has been introducing the Leonardo technology to the U.S. market.

Harry Covington

USA Harry Covington is President and Owner of Ferry Industries, Inc., Akron, Ohio. Harry has served on the ARM International Board of Directors and is a recipient of the ARM International Hall of Fame award. He has been a frequent presenter at rotational molding conferences throughout the world. Covington holds a BSME from Virginia Polytechnic Institute.

Mark Kearns

North Ireland Mark is the Rotational Moulding Research Manager of the Polymer Processing Research Centre at Queen’s University of Belfast. He is a Chartered Chemical Engineer with a M. Phil Degree in Rotational Moulding. Mark manages rotational moulding research and development projects for companies across Europe, Australasia, and North America.

Celal Beysel

Turkey Celal is Chairman of Floteks Plastik of Bursa, Turkey. An innovative leader in the rotational molding industry, Celal is active in business and political organizations. He has authored numerous articles published in various newspapers and magazines. A graduate of ETH Zurich as a Chemical Engineer, Celal speaks four languages fluently (Turkish, English, German and French).

Subscribe to RotoWorld®. Your best source for educational news and product information in your industry. For more information call, 512.894.4106. Subscribe online at 14101 Highway 290 West, Bldg. 1600-B, Austin, TX 78737 USA • 512.894.4106 • Fax: 512.858.0486

JANUARY-FEBRUARY 2012 • Rotoworld®

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Anders J. Stone (Andy) was born and raised in Northern Minnesota, the oldest of six boys who inherited his father’s mechanical abilities (started fixing lawnmowers when he was 6, rebuilding outboards, motorcycles and snowmobiles at 12 and built and drove American muscle cars as a teenager). Andy is a lifelong motor head and inherited a musical gift from his mother. He is also a lifelong musician, having played the piano for 40 years and performing on Sundays. A Hibbing High School Graduate (1977), Andy is celebrating 32 years of marriage to his high school sweetheart Lisa. He received a BA Economics, Summa Cum Laude: SCSU, St. Cloud, MN in 1987. Andy has had several careers within the state of Minnesota including mining, trucking, being self-employed, farming, manufacturing and raising four sons. Andy joined Stanley Widmer in 2009 as Operating and General Manager, building, testing and marketing the 7 meter prototype. He is an effective and enthusiastic leader with strong leadership and team building skills and has a successful career leading and building companies through recruitment, motivation and development of long-term teams to achieve long-term results.


Mitt Romney draws more than 1,000 in three stops

up f r o n t

NORTH LIBERTY, IA USA – Mitt Romney drew about 600 people to a rally held in North Liberty, IA, one of the largest crowds he’s seen all year. The turnout meant more than 1,000 people saw the former Massachusetts governor during three stops. Last night, the campaign said a Romney speech drew about 800, including people in an overflow room at a Davenport hotel. For months this summer and fall, it wasn’t clear if Romney was serious about winning Iowa. He campaigned here less often than his Republican rivals, but his recent events are drawing better than anyone else’s. The North Liberty event, held at a Centro Rotational Molding factory, featured an energetic candidate talking about his plans to turn around the U.S. economy. Romney touted the idea of giving Americans freedom to innovate, create new companies and hire more people. “Government doesn’t create jobs. American people create jobs for one another with their industry and innovation,” he said. “…I want to make America the best place in the world for entrepreneurs, innovators, businesses large and small, because I want to make America the best place in the world for jobs. If we have people clamoring for more employees, that means wages go up.” William and Sharon Oglesby of Iowa City said they were pleasantly surprised by the size of the crowd that turned out for their favorite candidate. William Oglesby, 79, said Romney seemed looser and more relaxed than usual. “I think he was overwhelmed by the reception.” Sharon Oglesby, 71, predicted Republicans would get over their divisions and rally around Romney because he’s the most likely to win the presidency. “We think he’s the most presidential,” she said. “He’s articulate, and obviously he can think on his feet,” she said. She also said his pitch, as a successful businessman should be a winner during tough economic times. “Right now, I just don’t have any confidence in somebody who has just been a politician,” she said.

Finance Available for Plastics Firms 14th March 2012 | BPF House, London, EC2A 3JE London, England – This workshop style seminar is aimed at UK based plastics firms and brings together a select collection of expert speakers to cover key funding opportunities. The seminar will cover the main government led financial initiatives to assist UK based manufacturers including R&D Tax Credits, finance available for exporters, funding for training and energy efficiency financing. In addition the seminar will feature presentations on funding growth from expert speakers from The Business Growth Fund and Barclays Corporate. For more information, contact the British Plastics Federation, 6 Bath Place, Rivington Street, London, EC2A 3JE, Phone: +44 (0) 207 457 5047 | Fax: +44 (0) 207 457 5045, Email:, Web:

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New Chair for BPF Rotational Moulders

The British Plastics Federation is delighted to announce the appointment of Karen Drinkwater, Founding Director, JSC Rotational LTD, as the new Chair of the Rotational Moulders Group. Karen Drinkwater is a former Commercial Development Manager in the logistics and contract packing industry. She has a degree in Agricultural Economics from University of Wales, Aberystwyth and set up JSC Rotational Ltd, a rotational moulding business with her husband, Mark Drinkwater, in 2003. Karen stated on her appointment ‘I believe that there is great potential for the UK Rotational Moulding Industry within the coming years and it is wonderful to be given this role to help promote further interest in our sector.’ “The Rotational Moulders Group is extremely grateful to my predecessor Martin Spencer who decided to step down as chair after several years in office. Martin worked tirelessly for the Group and his hard work was clear to see in the success of the ARMO Conference in Belfast in 2008 and the direction he took in bringing BPF Rotational Moulders closer to the design community with a programme of seminars,” Drinkwater said. Karen wants to build on Martin’s achievements particularly the interface with designers and sees considerable scope for new membership. Meanwhile Martin will remain the Groups representative to The Affiliation of Rotational Moulding Organisations (ARMO).


Wastequip Launches its Organics2Go Program for Organic Waste Charlotte, NC usa – Wastequip, the leading North American manufacturer of waste handling and recycling equipment, has launched its exciting new Organics2Go program for the safe and easy collection, storage and transport of organic waste. Key to the program’s success is a waste audit. Through the audit, Wastequip can customize a solution to meet any customer’s needs. Each program is designed based on the volume of organic waste typically generated at a site, as well as other customer priorities such as employee safety, product shrinkage, appearance and odor. Wastequip will then recommend a system that will help the customer reduce disposal costs, improve safety and meet sustainability objectives. The Organics2Go line includes a wide range of products for the safe collection, storage and transport of organic waste including containers, carts, cart lifters, biofiltration systems and digesters in a variety sizes to nearly any organics recycling or disposal need. Wastequip has introduced a series of specially designed containers to work in conjunction with the BiobiN® patented biofiltration system. The BiobiN system creates an aerobic environment for organic waste to minimize odors and the attraction of pests, allowing more time between pickups. Containers designed to complement the BiobiN system include a plastic organics front end load (FEL) container with a trap door lid for safe, easy loading. There are also several steel containers ranging in size from 3 to 20 cubic yards including the backpack container designed to eliminate spillage when the container is emptied as well as a steel organics front end load container and a steel roll-off container.

Wastequip also offers a full line of Toter brand stationary containers, two wheel carts and caster carts for collecting and transporting organics. These carts are manufactured using Toter’s Advanced Rotational Molding process for maximum durability in handling heavy, wet organic waste. In addition, Toter lifters offer an easy method for container emptying, improving employees’ safety and efficiency. Wastequip offers a food digester, a self-contained, continual feed organic waste disposal system for customers that wish to reduce the volume of their organic waste. The digester biologically converts food waste into compostable material, reducing food waste by 90 percent and dramatically lowering hauling costs. “Wastequip launched Organics2Go to be a leading provider of organic waste and recycling solutions for haulers and end-use customers,” said Anne Brantley, containers product manager for Wastequip. “We are excited to offer a complete program that addresses our customers’ organic waste handling needs.” About Wastequip Wastequip is the leading North American manufacturer of waste and recycling equipment with an international network of 25 manufacturing facilities and the most extensive dealer network in North America. Wastequip’s broad range of waste and recycling equipment and systems are used to collect, process and transport recyclables, solid waste, liquid waste and organics. The company’s brands include Wastequip, Toter, Galbreath, Pioneer, Accurate, Cusco, Mountain Tarp and Parts Place. On the web at

Norwesco Launches New Line Of Seamless, One-Piece, Low Profile Septic Tanks St. Bonifacius, Mn USA – In March, 2012, Norwesco will introduce a full line of low profile, seamless septic tanks. The new tanks will be available in the most commonly used sizes -- 500, 750, 1,000, 1,250, and 1,500 gallons, and will be available in single and double compartment versions. The new tanks are manufactured

using Norwesco’s proprietary stateof-the-art rotational molding process. Norwesco’s rotational molding construction ensures uniform tank wall thickness and maximum strength. The new low profile tanks also provide several advantages when compared to septic tanks made of traditional materials. Their lighter weight

makes them easier to transport and install, and the combination of the low profile and ease of installation make the new tanks an ideal choice for all installation sites. For more information, go to www.

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up f r o n t

Organics2Go is a Turnkey Solution for Organic Waste Collection, Transport and Storage


Amiantit Wins Shield in 2011 HM’s Cup Awards

up f r o n t

SULTANATE OF OMAN – Amiantit Oman, one of the Sultanate’s largest manufacturing companies has won a Shield for His Majesty’s Cup Award 2011. Amiantit’s CEO Banerjee received the cup from Sayyid Hamoud bin Faisal al Busaidy, Minister of Interior, who was the chief guest at the awards ceremony held at the Al Bustan Palace Hotel to felicitate the winners recently. Other VIP’s present included Saad bin Mohammed al Saadi, Minister of Commerce and Industry and Khalil Abdullah al Khonji, Chairman of Oman Chamber of Commerce and Industry (OCCI). “This is the sixth time that we have received this honour. We believe that our success can be attributed to the commitment of our employees who are motivated by a need for excellence and constantly strive for quality performance. The award serves as an encouragement for us at Amiantit, to continue putting in sustained efforts towards delivering quality through our entire range of products and services,” elucidates Banerjee. At the HM Cup, companies were broadly divided into three groups — those with investments exceeding RO 3 million, companies with capital

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investments not exceeding RO 3 million and those companies which have won more than 5 times. The winners are decided on the basis of factors such as — localisation of employees, marketing, financial performance, value added services, use of local raw materials, integration with other industries, efficiency in production, quality of products and application of environmental security and safety systems. During the competition, the companies were inspected by a panel of judges to ensure compliance with the stipulations of the competition. Amiantit Oman, is an ISO 9001, 14001 and OHSAS 18001 company,

fully committed to delivering quality through its entire range of products and services. Having a diverse product range, the company is a joint venture of Omzest and Bahwan Groups, and is a stellar example of leadership through innovation, sustained growth and quality consciousness. The company’s products enjoy unrivalled leadership in Oman’s construction and infrastructure development sector, and the product range is split across five verticals namely PVC, HDPE pipes and fabrication products, Rotational molding products, Glass Reinforced Concrete applications and Glass Reinforced Plastic products.

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Spotlight on Merrifield Man’s Brother on Anniversary of Tucson Shooting

up f r o n t

MERRIFIELD, MN usa – Bob Badger of Merrifield watched television set as news outlets marked the first anniversary of the shootings in Tucson, which took the lives of six people and wounded 13, including Rep. Gabrielle Giffords, D-Ariz. Badger’s older brother, Retired U.S. Army Col. Bill Badger, was among the wounded and was credited with grabbing the gunman’s wrist and pushing him to the ground. Col. Badger woke his brother that fateful day and opened the conversation by saying that he had been shot in the head, but was OK. The army veteran didn’t want his relatives to worry, but Bob Badger had not yet heard broadcast reports of the shootings. Bob Badger said the bullet didn’t penetrate his skull, although it made a three-inch gash in his head. His brother later told him he had never been shot in the service. He had been commanding officer of a helicopter training center. The anniversary of the shooting incident is Sunday. Bob Badger owns Fab Four, a Merrifield area business that fabricates and machines aluminum molds for rotational molding.

Jeco Collaborates with Purdue University and NDEMC PLAINFIELD, IN usa – Pallets from Jeco Plastic Products— designer and manufacturer of plastic pallets and containers for the worldwide printing and automotive industries since 1973—can now be made stronger than ever as a result of a collaboration with Purdue University and the National Digital Engineering and Manufacturing Consortium. The collaboration provides Jeco with access to incredibly powerful computers, which are used to perform stress calculations and demonstrate to customers that plastic pallets can perform as effectively as metal pallets in many situations. Recently, Jeco was able to significantly strengthen an existing pallet design by making structural changes as a result of detailed analysis. Commenting on the collaboration, Jeco Plastic Products Craig Carson commented: “Our work with Purdue University and NDEMC put powerful tools in our hands and enables Jeco, a relatively small company, to differentiate ourselves and demonstrate that our products are superior to those made of metal in many cases. Jeco plastic pallets are stronger and last significantly longer than wooden pallets. They are much lighter in weight than metal pallets, and can be designed to hold much larger loads that would seem possible. The calculations we now can do enable us to develop plastic structures for a wide variety of applications.” Additional information about the Purdue University and NDEMC programs which benefit Jeco may be found at https://

Research and Markets: The Future of North American Rotomolding ( has announced the addition of the “The Future of North American Rotomolding” report to their offering. Since researching and publishing our original technical/economic analysis of the North American rotational molding marketplace in 1995, Plastics Custom Research Services (PCRS) has become the acknowledged leader in this field. We have periodically revisited this business and provided updated analyses - in 1997, 1999, 2003 and 2008. As regional rotomolders recover from the Great Recession of 2008-2009 we believe it is timely to assess the impact of this disruption on these processors and the companies on their supply chain

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and to project their prospects for future growth and development. Based on this new research program we believe we can offer a compelling retrospective and preview of the evolution of this business. Over time the rotomolders in this region managed to penetrate diverse applications in virtually all markets where structural plastic parts play a role. From the 1940s when the original commercial practitioners of this process opened for business up through the 1970s there were gradual improvements in all aspects of the process - machinery,

materials and molds. Rotomolding evolved from a primitive art to a sophisticated repeatable science, capable of turning out parts of ever-greater design complexity. With improved competitiveness with other structural plastic part processors and converters of non-plastic materials regional rotomolders’ sales boomed in the 1980s and the first half of the 1990s, often registering double-digit annual growth.


Jean-Charles Henni President Elected AFR President

On the occasion of its Directors Board Meeting on January 13, 2012, the Francophone Association of Rotational Molding (AFR) has elected a new President: Jean-Charles HENNI (Rotoplus - Charleville Mezieres FRANCE). Henni succeeds Olivier Perrier (RAIGI - ROUVRAY SAINT DENIS - FRANCE) and is now fully dedicated to organizing and presiding over the next World Congress of Rotomolding “ARMO 2012,” which will take place in Lyon, France September 30 – October 2, 2012.

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Carl Dobrzeniecki: In Memoriam (1954 – 2012)

up f r o n t

A true leader and innovator in the Rotational Molding industry, Carl Anthony Dobrzeniecki of Farmington, MO, passed away at home surrounded by his loving family on Tuesday, January 3, 2012 at the age of 57 years. Carl was born on July 9, 1954 in Cleveland, Ohio, the son of the late Arthur Joseph and Dolores Veronica (Warnock) Dobrzeniecki. Carl was raised in Northfield, Ohio where he graduated from Chanel High School. He went to Kent State University in Kent, Ohio where he earned an Architectural Degree and Carl began working for Little Tikes Company in Macedonia, Ohio in the mid-seventies. He worked his way up in the company from a rotational molding machine operator to Operations Manager. As the company grew they moved their plant to Hudson, Ohio where it exists today. Carl moved to Farmington, Missouri in the late eighties where he took a position as VicePresident of Operations with Iron Mountain Forge. When the company was sold to Little Tikes Company in 1992, he stayed on for five years while co-founding Innovative Companies, which was organized in 1994. Innovative is currently in operation where Carl held the title of President. In 1998, Carl founded The Molding Company in the Industrial Park in Farmington, currently operating as Forte Product Solutions. “I founded the company because I thought there was an opportunity to bring my experience of high volume rotational molding to the custom market,” he said. After two years of initial and dramatic growth, Carl said that the year 2000 was a foundation-building year due to all the growth and development that occurred. He was named President of the Association of Rotational Molders International in 2000 – 2001. “With the great dedicated group of volunteers that support ARM, nothing stays the same. The only constants are the continuous evolution and development of the Association’s activities and the enthusiasm of the ARM membership in supporting the rotational molding industry,” he once said. Carl had his own brand of dreams and business style. His apparent and successful credo was to look straight ahead and listen to his customers, solve problems, innovate and challenge himself. He maximized the resources he had. His forward outlook, attitude and sheer determination to reach his goals in life and business underscored his journey in the rotational molding industry and served to predict his becoming the first licensee to step up to a new rotomolding technology, TRIP molding. “TRIP molding expands the range of applications into any product or market. It allows rotomolders

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to achieve injection and blow molding characteristics such as living hinges, solid flanges and multi-compartment tanks in a rotomolding application, things you cannot do through conventional rotational molding,” he said. In June of 2005, Kitterman Plastics and The Molding Company (TMC) announced a merger of the two companies. “This is an exceptional combination as it brings together each company’s respective heritage in the molding industry and deep-seated histories with specific account bases,” said Brad Robertson, president of Kitterman Plastics. Kitterman began plastics manufacturing in 1955. Carl Dobrzeniecki founded TMC in 1998, after his long tenure with Little Tikes’ toy division in Hudson, OH and the Newell-Rubbermaid commercial plan facility in Farmington, MO. “With an abundance of synergies, combining the expertise and services of our two companies will provide exciting new opportunities for all of our customers. The new company will have a balanced mix of proprietary products and custom manufacturing,” he said. Together the two companies exhibited a proven track record of leadership, innovation and nearly seven decades of industry experience.


Laundry Carts Continue Growth for Rotational Molding Company

(PRC) Granger Plastics Company is seeing a growing interest in durable, high quality laundry carts, a necessity in many industries. Due to this demand, GPC is now offering an expanded line of laundry carts and recycling carts. Laundry carts are a staple in many industries from factories, recycling centers to high end hotels and resorts. Many laundry carts and material handling carts are cloth based and become dirty and deteriorate quickly. Using plastic allows the laundry carts to be easily cleaned, stored and maintained. High quality durable construction gives the laundry carts a long life span and stretches the money spent by companies pinching every penny. The polyethylene construction is also much more versatile than fabric counterparts, which can quickly become unsightly. Granger Plastics Company offers a variety of laundry carts in many sizes and colors. They are nestable and stackable for easy storage and come with a variety of caster options. There are several options offered for company identification including stenciling and special order graphics. GPC’s laundry carts can also be used for many different material handling needs and stand up to many applications. Please visit for a complete listing of sizes and options. Granger Plastics Company is a Rotational Molding Company offering only the highest quality products. Visit www.grangerplastics. com for more information about GPC. For more information, contact Granger Plastics Company, 1600 M.A.D.E., Industrial Dr., Middletown, OH 45044, USA,, and email: january-february 2012 • Rotoworld®

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up f r o n t

Carl was very clear about his beliefs and philosophies in life and business. His approach was that when pursuing something new with some risk involved, one has to do their homework, but there comes a time when you just have to take a chance and go for it. “You can over analyze anything and miss the window for opportunity,” he said. Carl knew about running a company and he knew about rotational molding. The vast majority of his years in rotational molding were spent associated with companies producing their own proprietary products. From high volume consumer products to large complex commercial products, his direction was to take what he had learned from these markets and bring them into the custom rotational molding market. He once said, “Our success will always be gauged by our reputation in the industry, the smiles on our customers’ faces, our employees safety and happiness and Christmas cards from our bankers.” Carl’s leadership style had an underlying axiom, “treat people the way you want to be treated and that was a philosophy he chose to live by both personally and professionally. “There are so many ups and downs in business and in life, the one thing that should remain constant is treating people with respects,” he said. He also believed in the good attitude theory. “Attitude is everything. You can have all the skill, knowledge and experience in the world, however, it is the way you treat your customers and employees and the way you deal with adversity that brings it all together,” he said. As a community minded person, Carl was a current member of the Board of Directors for U. S. Bank; Mineral Area College Foundation board member; a member of the Farmington Industrial Development Authority and a supporter of Boy Scouts of America. Carl married the love of his life and soul mate, Christie (Montello) Gaborick on October 27, 1990 at the Farmington Presbyterian Church. Carl enjoyed life and was happiest sailing on the ocean on his thirty-eight foot sailboat with his wife as first mate. He also enjoyed music, playing guitar and tending to his backyard vineyard. He was the ultimate family man who enjoyed spending time with his family and friends. His grandchildren were the light of his life. Carl is survived by his wife, Christie, his children, Benjamin, Jennifer, Kate and Jay; three grandchildren, Sydney, Jack and Peyton; siblings, Michael, James, John, Joseph, Robert, Judith and Charles and numerous nieces, nephews, cousins, extended family and friends. A Memorial Service was held on January 5th at All Saints Episcopal Church in Farmington. Memorials may be made to the American Cancer Society or to Barnes Jewish Hospital Cancer Research.


Viso Launches Juju and Archie Floor Lamp Collections Canada-based firm Viso has launched the Juju and Archie lamp ranges. Both collections are designed by Filipe Lisboa and come in a floorstanding version. The body of the JUJU floor lamp sports the form of a tall hourglass. The look is complemented by a large shade which can be customised to meet individual tastes. The luminaire dons a high-gloss automotive finish with its base offering options of black and white tones. The Archie lamp imbibes a contemporary design with an overarching shape. The main light source of the lamp is contained within a suspended glowing globe in the top portion of the lamp. The base of the luminaire is also illuminated. The item is formed of rotational molding and comprises a brushed stainless steel finish. It is ideal to be used in both indoor and outdoor areas such as living room sitting space, and the deck.

up f r o n t

20 |

RotoworldŽ • january-february 2012

july-august 2011 • Rotoworld®

| 21

Leisa Donlan, ARMA CEO


Crossing Barriers with Gough Plastic’s Track Pad & Poly Gabion System Continues A History of Caring about People and the Planet with a Passion.


ustralia’s coastline is sand based and covers almost 60,000kms in addition to a vast sandy dessert in its centre and huge sandy tracts of land in its outback areas. With a relatively small population of 22 million, communities can be isolated by hundreds of kilometres of unsealed roads. These roads are vital to ensure services get through, yet existing road structures experience anything from severe damage right up to total failure in these challenging environments. Most failures currently occur due to the inability to secure them to the riverbed or sandy bases and failure of the structures means that roads can be impassable for months. Of course these issues aren’t only an Australian problem. Any area of the world that requires vehicular access in sandy or loose soil has the same challenges and many countries around the world have remote river crossings where the cost involved in building traditional Photographs courtesy of Fractal Division Photographics

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Rotoworld® • january-february 2012

concrete style structures is just not cost effective. One company has been working to find a better solution with global potential and to replace traditional materials with a rotationally moulded polyethylene system. Australian rotational moulder Gough Plastics is based in stunning Northern Queensland, home to the world famous Great Barrier Reef. The company is a Research, Design and Manufacturing specialist, which focus on new products from conception through to installation. Built on a strong base, which gives both flexibility in operation and security of existence, it is this family unit, which will continue to steer the company into future growth and expansion. Gough Plastics began working with their partner Base IGI, a local consulting firm, who works closely with Australia’s remote regional local government to try and find a better solution to the constant maintenance required in local sandy river crossings. Base IGI’s goal was to help the authorities provide the most cost effective delivery of services to the people of those communities. IGI wanted to put forward a better solution rather than doing the same thing again, which basically would have meant the crossing would have failed again at some time in the future. The new system had

Installation of the head wall on Mitchell River crossing in North Queensland.

to be designed for heavy vehicle and machinery traffic over delicate or unstable terrains. Simon Gough, the company’s Director in charge of Sales & Product Development says, “GP is well known for

Checking levels on the crossing prior to installation of the system. Figure 1: Total Booth Frankfurt Motor Show 2011

their unique way of thinking outside the square. The initial meeting was the usual case of a white board and a whole heap of ideas being thrown around. We went away from that meeting and quickly sat down with the product development team to hatch a plan. We had to design a system that would be able to be delivered in kit form, but be able to be assembled into a one-piece structure when completed. The engineers were very excited by what we had come up with and the project very quickly progressed to 3D models, engineering calculations done, the relative consultants involved and the project costed.” The new system would also deliver substantial cost savings due to the ability to utilize the local construction materials and very rapid speed of installation compared to traditional structures were key factors in convincing the clients that the system would do the job and be installed in a cost effective and timely

january-february 2012 • Rotoworld®

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Local helicopter pilots checking the progress of the new crossing.

manner. The North Queensland region of Australia basically has two seasons, the wet and the dry. All works need to be carried out in the dry because once the wet sets in the gravel and black soil roads in these areas are closed for months at a time and the only access is by air. Gough Plastics have an inclusive culture when it comes to product development. Many people were involved and together the team brought the project to fruition. The time frame from initial meetings to producing the first products from the mould was under 6 weeks. A phenomenal effort by all: Gough Plastic’s own internal sales and product development team worked closely with two external engineering firms during the development to meet the government requirements for funding and construction approval.

24 |

Building a sand island to form the crossing.

Water flowing over the completed crossing.

Rotoworld® • january-february 2012

The rotational moulding process brought out some challenges. Simon Gough responds, “As a world first product we had to think very much outside the square, we knew we were going to use our track pad system as the road surface and we knew how it performed as we have been using it for quite a few years in national parks as a road system for remote and difficult track areas. We had never used it before in a situation where it was going to be submerged, flooded and subjected to so many forces from water and river bed change. The key component to the whole system is the Poly Gabion or PolyG. Gabion Walls date back to Roman times and they work. What we had to do was design, engineer and construct a product that would enable us to tie the whole structure into one piece unlike any rock gabion design. The secret to the whole

design is no matter what nature threw at it; it would hang together and not be broken up. It should be remembered that we were designing a system to replace a concrete structure weighing hundreds of tons that had been washed up to 3 kilometres downstream by the wet season monsoon flooding.” The required time frame was extremely tight for such a technically challenging project. The company not only had to meet the engineering challenges, but they had to make sure the product was freight friendly and could be handled on site with ease. The system has application in low-level sand through to rock bed snowmelt streams and rivers that experience dramatic variations in stream flows. The extreme variations in flow usually result in serious bridge or crossing damage. The crossing is designed not to impede the flow of the river at all and be there when the water level drops to a safe crossing height. The river crossing system itself consists of two major pieces. The PolyG part of the system is a four-piece mould constructed of fabricated steel and manufactured in house. To mould the part, the company used a combination of standard Polyethylene tank grade material from local producer Qenos. To put the system together the company had to design and engineer the galvanised steel connector plates and injection moulded pins. The grid system is formed using the PE track pads and a range of PE CNC machined connector plates, pins and screws or nylon bolts. Hydraulic pressure testing of the parts for a load of up to 10 tonne was performed and sectional cuts confirmed good wall thickness was achieved. PolyG can be filled with several materials including sand, soil or concrete, depending on the requirements of the installation. To realise the final design, the

company worked together with internal and external designers and engineers using 3D modelling to integrate with the CNC machinery at the mould shop. The mould and shot weight together for the PolyG comes in at around 1000kgs and the company notes the arms on their Rheinhardt carousel machines have been built to handle the loads. The design for the PolyG was made as simply as possible however it required hinging panels in the mould due to undercuts that create strengthening ribs, so it was necessary to use a four piece mould. Each product weighed 220kgs so, in line with Gough Plastics worker safety guidelines, the design had to allow working from the ground and special inserts were used to lift out the product from the mould with the unload and reload time in sync with the machine

six inserts that form pockets. The track pad is made using polyethylene micropellets, which have the necessary flow properties to work with the complicated geometry of the mould. Andrew Gough, the company’s Director in charge of Production states, “We were very lucky with this project that Henry and his team at Base IGI are locals we were able to use local expertise which enabled us to expedite the whole process. To expand the market and bring the product to the rest of the market in Australia will take quite a bit of doing but Rome wasn’t built in a day and we are enthusiastic about the benefits of the system to remote communities everywhere.” The development process has brought more knowledge and experience to the company with the systems being well received by authorities. CEO Ian Gough states, “There was a phenomenal amount of work that went into getting the project off the ground and the end users are grateful that they can now get to town, buy their groceries and get their children to school. Our partners are excited that we now have a solution to a continuing challenge and the system has been well received in general.” The PolyG river-crossing concept has been used on two major projects with success and each project has allowed the company to assess the design and engineering of the system. There were minor changes made from project 1 to 2 and the results of these changes should appear once the river goes down and the developers can see the crossing again. One of them, the Dunbar – Koolatah Crossing on the Mitchell River is 400m long dual-carriage way. The Mitchell River has one of the largest catchments in Australia. The company has been operating from its Townsville base since 1989 and has successfully completed projects in Brazil, Germany, South Africa, Papua New-

We were designing a system to replace a concrete structure weighing hundreds of tons that had been washed up to 3 kilometres downstream by the wet season monsoon flooding.

operation so no cycle time was lost. Gough’s Trackpad is a modern polyethylene version of Marsden Matting, a standardized, perforated steel matting material originally developed by the United States at the Waterways Experiment Station shortly before World War II, primarily for the rapid construction of temporary runways and landing strips. Marsden matting consisted of steel strips with holes punched through it in rows and a formation of U-shaped channels between the holes. Hooks were formed along one long edge and slots along the other long edge so that they could be connected to each other. The short edges were straight cut with no holes or hooks. To achieve lengthwise interlocking, the mats were laid in a staggered pattern. The Gough Plastics PE track pad is manufactured in a complicated 8-piece cast aluminium mould in two halves and

january-february 2012 • Rotoworld®

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The crossing during installation of its total 400 metre length.

Guinea and throughout Australia. They take great pride in their achievements in all fields, especially those that have a bearing on Health and Environmental matters. And the company has a long history of helping the planet, particularly in the local Sugar Industry during the Second World War when grandfather Herbert Gough spent much of his time helping the Italian migrant farmers in the Lannercost area of the Herbert River Valley, Queensland, to remain viable during the times of internment. During his time as a farmer Peter Gough was responsible for developing a cane planting system, which was to become the accepted norm in the Sugar Industry worldwide before his move into plastics and specifically rotational moulding. It has been this sort of resourcefulness and willingness to succeed and overcome challenges, that

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RotoworldŽ • january-february 2012

has seen a family company grow into a dedicated team of professionals striving for excellence under the banner of Gough Plastics. Most recently in their long history, they have successfully made the move from a small family based company into a well governed and truly corporate style business that is able to balance the family dynamics with good business through professional planning. The third generation version of the company includes three brothers who all take responsibility for various aspects of the business with Ian Gough as CEO and running the show, Andrew Gough focussing on Production & Product Development and Simon Gough working in Sales & Product Development. The three brothers acknowledge that this sort of ground breaking new product development is only possible with an amazing team on

staff and they credit the success of the new river crossing system to their team’s refusal to acknowledge something is impossible. In an economy that continues to struggle into recovery and an industry that is suffering along with the rest of the global manufacturing sector, its innovative companies such as Gough Plastics that work with limited but sophisticated resources in highly specialised sectors that prove rotational moulding still has a world of possibilities. The river crossing system has worldwide potential and not only for Gough Plastics. The company would be interested in talking to anyone who feels there may be some local potential for this global first in rotational moulding. If you would like more information simply go to or email Simon Gough


When we think of energy efficiency, the obvious focus is on the shop floor operations, including the equipment used in the production process. However the actual facility, during productive and non-productive times, can be a significant drain on your energy budget. Welcome to the 1st of the 2012 RotoWorld® Energy articles. How old is your facility? Most of us, who are established in the industry, operate from real estate that is 20 years or older. That’s not necessarily a bad thing as building standards have improved over the years to incorporate increasing elements of heat loss prevention. However, operating from a 50-year-old facility presents more challenges, where there may be little or no insulation, the structure might be riddled with obvious (or hidden) openings, and probably employs old lighting and electrical wiring. Our company produced, for many years, from an airport hangar built in the late 30’s (the airport served as a WWII pilot training center), so I can speak from experience. The facility was a nightmare to heat as evidenced by the cold temperature that greeted us, during winter, on the first shift of the week. I expect it is no different for those of you that operate from a fabric/steel frame facility today. Owners of these types of buildings should be aware of a simple calculation, using energy bills, to help identify the true cost of heat loss. Plot the monthly energy use (gas or oil) on a graph (energy use vs. month of the year). You should see a nice bell curve with the high values during the coldest time of

the year. Next plot the average (should be a straight line) on the same graph. Where the two plots intersect, the area of the curve above the average is what you’re wasting just to heat the facility! Wouldn’t you prefer to use that energy in your process and generate revenue to your bottom line? Consider these costs when you develop a business case to upgrade your facility. Another opportunity to save is by managing energy use during the “dark

facility down to the ‘dark time’ level you may find that some shifts perform better than others. It might be wise to standardize the shut down process. Document and establish procedures (like a pilot checklist) to avoid leaving on non-essential equipment. Some of the items to address include shutting down lighting and non-essential equipment. Look at night safety lights and security as well. Do you necessarily have to illuminate the entire property? Perhaps you only need to illuminate selected areas or you could target areas that could be shut off entirely after a certain hour. How about turning back the thermostats for cooling or heating during plant closure times. We provide plug-ins for our staff for block heaters on their cars. We found that by cycling them on and off every hour we saved a considerable amount of energy while still providing easy cold starts for our employees. Your office can also waste energy needlessly through leaving on computers and printers. Most of us don’t realize that these devices are continually drawing power even when they are not in use. Typically, computers are left on for no apparent reason. Establish procedures to shut them down, and try to utilize full-off switches (power bars). Include your office staff to brainstorm, as they are a great resource to determine and identify ways to reduce energy waste in this area of the facility. Remember to keep the effort moving forward and follow up with action and commitment.

“When transitioning your facility down to the ‘dark time’ level you may find that some shifts perform better than others.”

times”, when sections of the plant are not in use or when the office is closed. Ideally, when your facility is shut down during weekends or holidays, you should be trying to reduce the energy use to near zero (which is rarely the case)! Go through the exercise of shutting off all the lights, and all other obvious electrical devices. You’ll be surprised that your building continues to pull significant amounts of electricity. Spend the time to investigate what these sources are, determine if they are essential and find opportunities to reduce or eliminate this waste. Toyota Corporation is very active with this effort and they regularly perform energy audits known as “treasure hunts” in their car manufacturing plants. Although their focus is primarily operational energy use, they also try to include at least one shift with no production. These studies help determine how well and how fast they can bring the energy consumption down to near zero. When transitioning your

january-february 2012 • Rotoworld®

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e n e r gy

Your facility can be a significant drain on your energy budget!


5th Annual Nordic ARM Conference Highlights in Södertälje, Sweden The 5th Annual Nordic ARM Conference took place February 6-7, 2012 in Södertälje, Sweden. Association President Ronny Ervik, ØPD Solutions AS, welcomed some 80 attendees representing several countries. Ervik introduced and thanked the conference sponsors and Association directors and served as Master of Ceremonies for the event.

2012 Nordic ARM attendees tour the Nordisk Wavin Rotational Molding plant.

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Rotoworld® • january-february 2012

On the first day of the conference, there was an impressive

including four massive through holes and a total weight of

line up of presenters on timely topics, and attendees enjoyed

1250 kg. “The biggest challenge was the weight of the mold,”

a first-hand tour of the rotational molding manufacturing

he said.

facility of Nordisk Wavin, A/S, which was sponsored by Wavin

Alongkorn Kanokboriboon, senior product development

A/S and MAUS. There was a special dinner in the evening

manager for SCG Chemicals, presented an interesting look

sponsored by ICO and Matrix. On the second day of the

at the Asia Pacific rotomolding industry and its product

conference, there was a special seminar presented by Dr. Paul

applications. He reported that the Asia Pacific geographic

Nugent on “Rotomolding - Doing It Right the First Time,” which

area covers 51 countries including West and East Asia,

was sponsored by Cipax, Uponor, RotoLink and Resinex.

Southeast Asia and Oceania, and includes 4.2 billion people.

Sergio Zilioli, sales manager for Persico, talked about

Total resin consumption for this area is 300 KTA and there are

several challenging projects that have been brought to success

approximately 1,000 rotomolders. “Products manufactured

in rotational molding. The first of these was innovative boats developed by Cipax in collaboration with Persico’s Rotational and Marine divisions. “The goal for this product was to develop a wide range of capable boats at a good price,” he said. He talked about a project involving the reverse engineering of a chair, which was successfully exhibited at the Milan Furniture Fair, made with a CNC mold. “Reverse engineering with CNC has made huge improvements compared to 5-10 years ago,” he said. Zilioli also reported about the use of liquid nylon with the Leonardo automated rotational molding machine, which is ongoing with a company in Russia. Walter Bonazzi of Polivinil Rotomachinery talked about energy saving improvement on rotomolding machines posing such questions as, “How much consumption of energy do I need?” Bonazzi said rotomolders are used

Dr. Paul Nugent, MNOP, and Ronny Ervik, ØPD Solutions AS

to dealing with temperature levels and cooking times and the

include 70% tanks and 30% others (ice boxes, septic tanks,

strategy is simple: The lower the better, reduce temperature

chemicals tanks, diesel tanks, kayaks, toy and playground,

and shorten cycle times. “The tactics are complicated:

furniture, decorative and agriculture, etc.),” he said. And,

increase the temperature and reduce cycle times or save

machines typically utilized are 80% open flame Rock n Roll

energy and extend the cycle,” he said. According to Bonazzi,

and 20% closed oven. “Approximately 49% of rotomolded

the real question is the cost of the process, and the lower the

product in Thailand is cooler boxes and water tanks,” he said.

better. “Big burners mean big capacity and we need to have

Dr. Eng. Claudine Porcel, Ico Polymers – a division of A.

a gas meter on the machine to monitor gas usage,” he said.

Schulman, talked about innovations at ICO Polymers. She

Bonazzi told the attendees that winning machines have gas

gave a history of A. Schulman Inc., which began in 1928

saving tools on board and big energy savings can be achieved

through the company’s acquisition of ICO Polymers in 2010.

through well-organized machine cycles.

Porcel covered Schulman’s worldwide locations and European

Oliver Wandres, MAUS, talked about opportunities for

production sites, customer services including material grades

the Rotomolding industry and intelligent mold performances.

and applications offered by the company.

“Price and lead times are often the most important aspects

Niko Päivinen, product development engineer for Uponor,

when selecting a mold, but there are other items of

talked about a project where design met with engineering

importance such as quality, accuracy, user friendliness, energy

at Uponor. The project took place in cooperation with the

efficiency, etc. We need to listen to molders as every molder

University of Art and Design, Helsinki, with a Master’s thesis

works differently,” he said. Wandres detailed a case study on

by Mr. Tatu Piispanen. The design drivers were: simple, smart

a sophisticated mold conception for an ICON box, a 6-piece

and quality. Simple to define products that are not complex,

cast aluminum tool for 3-layer production (PE/Foam/PE),

but clear in their expression and use, easy to install, use and

january-february 2012 • Rotoworld®

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Matz Svensson, Cipax

Dr. Paul Nugent, MNOP

Oliver Wandres, MAUS

Niko Päivinen, Uponor

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Rotoworld® • JANUARY-FEBRUARY 2012

Alongkorn Konikoriboon, SCG Chemicas

Dr. Claudine Porcel, ICO Polymers

Walvin Plant Tour

Fully functional products can still look good; design does not compromise engineering details. – Niko Päiveinen maintain and are usually simple to manufacture. Smart to define products that are a smarter choice, employ smart, innovative solutions, designed with the user in mind and environmentally smart or sustainable. Quality to define products that look and feel reliable and professional, visually express efficiency, have attention paid to the details and include a visible brand. He covered the importance of implementing design elements without compromising the technical aspects of the product. “Fully functional products can still look good, design does not compromise engineering details. Bringing in industrial designers and design guides can be easier than one would think, you can start light and use external experts until such time as you can bring a designer in house. Matz Svensson, Nordic ARM director, reported on Rotoplas 2011, a tradeshow dedicated to the rotational molding industry. “The show was attended by more than 300 with more than 100 of them rotomolders and there were more than 70 booths exhibited,” he said. Svensson gave some examples of what was shown at Rotoplas, which included: a new type of shuttle by Ferry Industries, a 3-arm Shuttle by STP, inner watercooling and fast heating pins for moulds by MAUS, vacuum in molds to avoid bubbles by Persico, a new X-link material CARB regulations by Matrix and new moldon graphics by Robstar. He reported that the next ARMO

Convention will take place in Lyon September/October 2012 and the next Rotoplas will take place in 2014. On the second day of the conference, Dr. Paul Nugent gave a seminar on “Rotomolding - Doing It Right the First Time”. Nugent covered typical problems and suits faced by rotomolders and reviewed common complaints and issues and the broader effect that such problems can cause. He presented typical reasons for disputes and gave examples. “Perhaps not all of these problems and issues can be avoided, but many of them could be if the right steps are taken at the outset,” Nugent said. Nugent also said such disputes can cause problems other than just money; they can distract you from your day-to-day business and affect your reputation and good will. They are more common that one might realize and only lawyers enjoy them. Nugent’s seminar also covered product performance requirements, good design practices, understanding materials and long-term performance, good process control, documentation, testing of materials and parts and information loops, among other pertinent topics. Sponsors for the conference included: Rotomachinery Group, Matrix, ICO Polymers, Ultra Polymers, Wavin, MAUS, Persico, RotoPlastic Morandi, Resinex, Cipax, Uponor and Rotolink. Stay tuned for the next Nordic Conference, which will take place in 2013 at a date and location to be announced. JANUARY-FEBRUARY 2012 • Rotoworld®

| 31

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Serving the Rotational Molding Industry Worldwide for Over 30 Years

The mission of the Association of Rotational Molders is to “provide tools that make good rotomolders and their suppliers great; and to increase the rotomolding marketplace.” For more information, visit the website at or contact the Association at 630-942-6589 or

President’s Message

2012 ARM Spring Executive Forum! It is hard to believe

the willingness of those same individuals to share their expertise

the Spring Executive

is amazing! This is a unique characteristic of the Rotomolding

Forum for all of ARM

Industry and one we never want to undervalue.

is just a few days

away; held this year

experiences germane to the Rotomolding Industry than these

at the exclusive Green

face to face meetings and conversations sponsored by ARM for

Valley Ranch in Las

the benefit of all the Membership. Books, Web Sites, E-Blurbs all

Vegas from March

can help, but a one-on-one with a Rotomolder with 40 years of

18th to 20th.

hands-on experience can do more for you and your company

This executive

There is no place more suited to learning and sharing

than a year of research and trial and error.

program is planned

to be a unique

presentations on Negotiations, Lean Safety, Tax Issues, Human

opportunity to

Resources and Executive “What’s Your Problem” sessions.

network with industry


The Spring Executive Forum includes dynamic

leaders, learn from experts in the field, play a little golf, enjoy

the company of your industry peers and even escape from the

presentations, the informal setting, dinners and receptions; event

weather we are all so tired of. I am excited to attend with the

the golf in the Nevada sun.

I am sure all in attendance will find value in these

60 or so Molders and Suppliers. We have a great meeting planned and there are always lively discussions in an informal

Hope to see many of you in Nevada in March!

personal atmosphere. I never leave the Spring Forum without taking back some valuable pieces of information that will impact our business.

In this extremely competitive environment, Rotomolders

and Suppliers need to avail themselves of every opportunity to

David Smith

improve their individual businesses, and through networking


and discussions during these meetings, we will gain valuable

Association of Rotational Molders

direction and answers from the leaders and experts scheduled to attend. We know the collective skills of all in attendance are a far greater resource than any single company can amass, and

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Rotoworld® • january-february 2012

ARM Report

Business Condition Results One of the many ARM member benefits is a monthly snapshot of industry trends based on a short survey distributed to our molder and supplier members. Each month we give our members two weeks to report on industry trends from the previous month and everyone who responds is emailed a summary of the results during the third week of the month. On the following pages you will find a few

Figure A

reports on the 12 months

the highest increase was 26% in January 2011 and the lowest

of data from 2011. For more data from up to 30 months as

was 4% in October 2011. All in all this was a highly positive

well as historical comparisons, ARM Members should review

report, slightly lower than 2010 but also much less volatile.

our monthly e-newsletter, Rotolink.

Our next graph (Figure B) reports our participants’ forecast

The first graph (Figure A) reports monthly sales compared

for the three months following when data was collected. We

the same month of the previous years. Our participants

have removed the data for participants who forecasted no

reported an average increase of 16% throughout the year,

change. The majority of participants throughout the year (54%) forecasted higher sales than the same period from 2010. On average 17% of our participants forecasted lower sales. When we asked about the back logs of our participants throughout 2011 (Figure C), on average 30% reported they were higher than the previous month and 36% reported they were lower than the previous month. As the year went on, there was a trend towards lower back logs. (The trend for those

Figure B

reporting No change january-february 2012 • RotoworldŽ

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ARM Report in back logs throughout the year was flat.) When asked whether they were optimistic or pessimistic about the next three months (Figure D), our monthly snapshots showed an industry that was becoming more pessimistic after the first quarter. Our members who take part in the monthly surveys in 2012 will be following this trend. Regardless, the average for the year showed 51% of participants optimistic and only 11% pessimistic. We have removed the data for participants who said they were neutral.

A Good Bet in Vegas: The ARM Spring Executive Forum

ARM will host the Annual Spring Executive Forum at Green Valley Ranch in Las Vegas this March 18-20. This popular networking program is geared to Rotomolding Executives and their Suppliers. Pat Long of Formed Plastics and Dec Crumley of SourceCorp will talk about how they returned $300,000 to the bottom line with R&D Tax Credits and how the process can work for other molders. Robert Hafey, who has worked in manufacturing for 40 years, will present a hands-on Lean Safety workshop that will give you the understanding to dramatically impact your operations as soon as you return to the plant. George Lucas,

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Rotoworld® • january-february 2012

Figure C

Figure D

Ph.D., has been active in business education, executive development, and organizational consulting since the early eighties. George will talk to the rotomolders in attendance about The Flawed Tactic of Compromise, The Four Viable Negotiation Strategies and the Pearls of Wisdom for Experiencing More Success with Less Stress in your Life. The meeting will also include a talk on Workplace Wellness Programs, Training and Retention in Rotomolding and an Executive-Level What’s Your Problem? A reception will be held on March

18, educational sessions on March 19 and 20 and an optional golf tournament on the afternoon of March 20. More information about the program is available at

The Benefits of Membership • iLibrary – A fully-searchable online archive of more than 700 technical papers and presentations. Available at • Sales Inquiry Notifications – We review sales leads – typically from companies seeking molders – and email them to our member companies. We actively advertise for leads on behalf of our members. • Financial Benchmarking Study – This annual study allows our molder members to see where their company stands in relation to the average and high profit molders in the rotomolding industry. This data is not available anywhere else. The study reports include specific recommendations to increase profitability. • Monthly Business Conditions Survey – The results of this survey are given to participants every month, to provide a snapshot of industry trends. • Regional Meetings – These meetings combine convenient locations, affordable pricing and valuable information to exceed the expectations of our members. The format is a single-day of various technical presentations geared to front-line personnel.

• Webinars – We provide hour-long sessions on issues important to the rotomolding industry. • Networking – We provide our members a valuable community of peers who are available for networking, technical insights and industry feedback. Our members have stated this is a priceless benefit. • Spring Executive Forum – This program creates valuable networking and educational opportunities for rotomolding executives and their suppliers. • Safety Award – This new award is part our strategic goal to make all of our molder members more effective and profitable. The award is given annually to the ARM molder member that demonstrates the fewest number of work-related injuries. • Annual Meeting – The premier event for rotomolders, their suppliers, designers and educators. Programming includes professional and industry speakers, group workshops, exhibition and networking. For more information on ARM or to join the Association, visit or email

• Cost-Savings Tips – Our board and committee leadership share cost-savings techniques on the members-only section of the website. • Rotolink – Our monthly e-newsletter announces upcoming programs, shares important industry news and profiles our members.

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Anders J. Stone, General Manager, Stanley Widmer Associates, Inc.

What’s Your

Dream? Everyone needs a dream. Stanley Widmer’s dream became reality. The Widmer boat hull flexes and absorbs the impacts produced at high speeds in rough seas. The hull is double wall rotationally molded out of high density cross-linked polyethylene (HDXLPE). It employs Widmer’s patented kiss-offs for strength. The impact G-forces are absorbed by the hull instead of directly translated to the occupants. Additional demonstrated material characteristics reveal the unsinkable nature of plastic, the ability to absorb blunt trauma from rocks/debris and explosives, superior abrasion resistance and puncture resilience. Furthermore, it does not crack, rust or need paint.

Widmer an

d his Spee

dliner afte

r a 92 mile

race in 1956


Photos are courtesy of Gus Gustafson.

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Rotoworld® • january-february 2012

are formed in the rotational molding process. One of the Unlike fiberglass that breaks upon impact and aluminum that mold sections has a mold surface for forming one of the hull distorts upon impact, Widmer’s flexible double hull boat is walls, that surface having one or more rows of V-shaped designed to flex to reduce G-shocks on the occupants. indentations projecting toward an opposite mold surface. The Widmer dreamed of a boat hull that could survive the V-shaped indentations have apexes that are spaced apart punishing wave chop dished out by Lake Winnebago. As a from the opposite mold surface by a distance that, during young racer, his Kiekhaefer propelled D-class wooden race the molding process, will fill with boat frequently required repairs after molten material to form a molded racing, and the ride was physically connection between the finished brutal. A boat hull that was doublehull walls. In another embodiment, walled rotationally molded, which a lattice structure is assembled to was less rigid and flexible, was the the mold and molded in between solution. This began his lifelong quest. side-wall components of the hull. Widmer first became aware About this same time, the Navy of cross-linked high density Special Warfare Center (NSWC) polyethylene in 1965, and his material began to investigate the significant studies convinced him this was the injuries can occur to the seamen right material for a boat hull. Crossin high-speed special warfare link does not zipper like HDPE. The boats. They were getting hurt chemistry goes something like this: during the ride (before their actual The peroxides added to the HDPE mission). The intense dynamic flash off in the furnace breaking linear Flexing loads are converted into tensile loads transferred into the inner and outer molded walls. forces experienced by a boat hull PE molecule chains in the process (free radicals). These free radicals attempt to and ultimately bond to while traversing rough seas at high speeds can be in excess of 20g shock loads. Chipped teeth, broken ankles and injured another free radical in its vicinity. The result is non-linear PE backs happen at these shock levels. The Navy began a “shock because of the chaos. It was described to me like this – tear mitigation” quest. Widmer’s idea was about to be tested. an envelope in a straight line and look at the edge, you can The US Congress, in its desire for a safer boat for the US see the fibers and they point in one direction, similar to linear Navy, contracted Widmer to design and build a rotationally PE. Now tear a mylar envelope – oops, you can’t. This is a major strength of cross-link. Fatigue tests support this analogy. molded double wall hull using thermo-plastic cross-link material and his patented “kiss-off” design. The Office of Cross-link also takes on properties of thermo-set plastic, Naval Research (ONR) worked with Widmer on the 7 meter meaning it has a memory. After being subjected to extreme design. The original design was for an Unmanned Surface distortion, cross-link will return to its “set” state. Vehicle (USV), which was prototyped with seats and controls In 1972, Widmer started an engineering company called for manned testing. The ONR Project Manager agreed on the Stanley Widmer Associates, Inc. in Minneapolis, MN. His original drawings and 3D models were created in CAD. day job was solving other people’s material problems, but Computer modeled Finite Element Simulations (FEA) also at night he was perfecting his boat hull design. The popular identified potential issues, which were addressed. The FEA mindset at this time was that there was a limit to the size that also demonstrated reduced G-Forces on the occupants due a rotationally molded part could be. How do you mold a part that is rigid enough for large part applications? Consider a piece of paper. By itself it has little strength. Add a second sheet of paper and the situation doesn’t really improve. Put some fluting between those sheets of paper, and you have the strength of cardboard. This concept of connecting the two walls of a rotationally molded product during the heating cycle was fully developed. Widmer put his ideas onto paper and filed for patent protection. In 2002, he received a patent for his molded “kiss-off”. The kiss-off is what makes rotomolding large parts possible.-It provides the internal structure necessary for rigidity and it does so at the tooling level. A rotational molded boat or equivalent floatable marine structure has parallel hull walls interconnected by rows of 2D and 3D CAD drawings were produced from Widmer’s hand drawings. spaced apart, molded V-shaped connectors. The connectors

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to the ability of the HDXLPE material and kiss-off design to absorb impacts and directly compared the results to fiberglass. From there, Widmer had to produce a full-size wood pattern of the boat, which was used to make sand castings.

The 7-meter basically required 2 very large tools, the 24 foot hull and the 24 foot deck. All the tools were made by our friends at Norstar Aluminum Molds and were cast aluminum. Pouring 2,000 pounds of aluminum is a story in itself. The hull tool (aluminum mold and supporting structure) was 10 thousand pounds! Our friends at Forté Product Solutions were willing and able to test their skills at molding this boat with over 300 inserts. The hull tool was filled with 1,400 pounds of ExxonMobil High Density Cross-Linked Polyethylene material (Paxon 7004) and cooked in their 25 foot rock-n-roll oven for

90 minutes. Our friends at ExxonMobil assisted with realtime telemetry data to assure proper temps were reached. They also followed-up with glycol tests to document that cross-linking took place. Several tool “seasoning” parts were produced. These proved invaluable in developing handling and cooling techniques, and also offered samples to confirm “kiss-off” conections occurred. The final parts were made. All the parts of this 7 meter hull are rotationally molded out of HDXLPE. These include the hull, deck, fuel tanks, hatch covers and trim tab. The assembly of this prototype occurred at Widmer’s Staples, MN shop in less than 2 months. It was outfitted with a single 250 hp, 4,300 rpm Steyr Motors MO256K43 Diesel engine on a monoblock design (head is cast with the block) with electronic controlled mechanical injectors. Propulsion is provided by an UltraJet 251 axial flow pump with a 9.8 inch diameter impeller. A ZF transmission was used to accommodate back-flushing of the jet intake screen and the opportunity to run the engine on land while in Neutral. Widmer’s prototype boat took its maiden voyage on Lake Osakis, MN on May 12, 2010. During trials, its first run achieved a top speed of 38 miles per hour. Testing included rock impacts, beaching, smashing docks, navigating 18 inches

Widmer and his 1/4 scale wooden model used to evaluate the CAD design.

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Finished boat hull being released from the upper half of the hull tool.

The prototype success has prompted interest from military and law enforcement worldwide.

of water and small arms fire. Widmer reported that the tests were successful and the hull performed well on S turns and panic stops. After Widmer’s testing, the boat went to Naval Sea Systems Command (NAVSEA) Naval Surface Warfare Center Carderock Division (NSWCCD), Combatant Craft Division Test and Evaluation Facility on Fort Monroe in Hampton, Virginia. Today, we need to transition from prototyping to production. The prototype success has prompted interest from military and law enforcement worldwide. The 7-meter hull performed so well that Vessel Hull Protection from the US Copyright Office has been requested. The successful hull design provides flexibility for multiple configurations. Different decks, helms, consoles, cabins, power and propulsion can be fitted onto/into the 7 meter hull. Commercial applications are also being designed and reviewed. We are contracted with (the Government’s purchasing website). We are discussing dealerships in South America, Australia and India. We are hoping to mass-produce this craft in Staples, MN. We have facilities planned and have researched construction of a 60 foot rock-n-roll oven to accommodate the 11 meter twin engine craft which incorporates Widmer’s patent pending truss system.

Widmer boats with “kiss-offs” (Patented) are designed to withstand blast, impact and/or structural loads when they are used to blow up mines, when moving through rough seas at high speed and/or when they are hoisted aboard another structure (e.g. another vessel or a platform). Standard hull designs currently used by naval forces and others requiring such performance are made of aluminum or fiberglass. Aluminum hulls do not withstand successive blasts well and fiberglass hulls break when moving through rough seas at speeds as low as 30 knots. Widmer boats are more flexible (less breakable) and thus more resistant to impacts from blasts and waves, unsinkable, resilient to small arms fire and cost effective to manufacture despite their relatively large size compared to conventional rotationally molded articles. Although the principles above are described and illustrated primarily with respect to boats, such articles are only examples. Components of structures could also be such articles. For example, walls or roofs of buildings and similar structures are possible, as are portions of containers, transportation vehicles, and the like. The strength and reduced weight provide the manufacture and use of structures previously believed to be “too big” for rotational molding. Examples include military or civilian bridge structures. Similar JANUARY-FEBRUARY 2012 • Rotoworld®

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examples include load bearing floors, walls and roofs for low cost housing, and deck planks. Further examples include the connectable sections of floating platforms. They could be used as modular floating deck platforms in shipyards, ports and other similar installations involving large marine vehicles or equipment (e.g., platforms for measurement or other types of equipment). The Future Stanley Widmer’s latest patent is an internally molded truss (patent pending). Rotationally molded plastic articles are typically limited to smaller sizes based upon the deflection characteristics of the material itself. This is why rotationally molded plastic parts have not been made larger than 25 feet. On the other hand, steel is very rigid. It’s also very heavy, expensive and it corrodes. We are developing the technology to combine the strength of steel with the benefits of plastic. We have designed an internal metal truss system that can be molded inside the plastic part for exceptional strength and resistance to buckling or twisting. In general, as the dimensions of a rotationally molded product increase, the amount of shrinkage increases, and also the amount of deflection (sag) in the finished product increases. The compressible truss addresses both of these problems by adding to the strength and rigidity of the finished product. The thermoplastic materials used in rotational molding are known to cause the molded articles to shrink upon removal from the mold by approximately 5% or less, typically approximately 3% in the case of polyethylene, the most common material. However, once shrinkage is complete, no further shrinkage or expansion is expected under normal circumstances. It is important to remember that due to the rotational molding process, all exposed surfaces of the molded-in truss will be covered with molten plastic material that will cool to direct contact with the truss. Thus, once the molded article has cooled and the compressible truss has contracted, the resulting article is extremely strong not only because of the inherent strength of the truss itself, but also because of the significant amount of surface area represented by the polymer/ truss interface. The combination of truss and plastic has significantly greater strength and may be relatively large (such as the 11 meter test boat we are designing), yet when it is exposed to substantial external forces, the compressibility of the truss keeps the assembly from being too stiff to absorb the applied forces. For more information contact Andy at 218.894.3466 or via e-mail at Visit The result of a dream -- Widmer’s indestructible boat.

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Design considerations must go far beyond the basics of CAD skills and technical expertise to attain a successful product. They must place the end user’s expectations and requirements at the top of the list of design specifications. If the end user’s needs are not met, the product will not sell. Many rotational molders and OEM’s mistakenly focus their attention on technical issues, often ignoring customer requirements. Molders are primarily concerned with production costs, tool design, cycle time and secondary operations. OEM’s on the other hand may be concerned with function and engineering related factors pertaining to material properties or stresses. The end user’s requirements are more complex and less obvious. Their significance is frequently closely associated with the application, competition and marketing strategy. Coordinated integration of product design with marketing strategy is routine for most successful companies. Product design features, pricing, appearance, quality standards and branding are usually carefully orchestrated to work with advertising campaigns and promotions along with other marketing activities. These product traits are developed as part of the design process. Good product design optimizes esoteric marketing requirements with quantitative technical requirements often the focal point of molders and engineers. Many rotational

molders often make the mistake of equating good design with parts that are optimized for rotational molding. This overly simplified correlation is very understandable based on their primary responsibility of molding good parts cost effectively. This perspective, combined with the advancements of CAD software, has prompted many molders to hire designers as part of their staff. Although the inclusion of a captive designer or staff within a rotational molding facility is a great asset, it can also introduce problems if

an objective understanding of the product and marketing requirements. These parameters must then be creatively expressed in a design which embodies an optimized balance of hundreds of factors essential for success in the marketplace. Rotationally molded products, which are primarily judged by customer perception, include kayaks, furniture, toys, floor cleaners and recreational products. Highly competitive marketing programs distinguishing one kayak manufacturer from another are exclusively based on customer perception as well as performance. The overall shape, attention to details, special conveniences, surface finish, graphics and many other design related features play a major factor in customer preference. Successful designs express key product attributes to reinforce the marketing messages and product branding displayed in advertisements. Needless to say these emotional characteristics which sway decision making before a purchase must be seamlessly integrated with all the technical requirements for production and performance. A comprehensive design package addresses all these parameters. The results often lead to overwhelming customer demand, sales and profits. Just look at any Apple when a new product is released.

“Coordinated integration of product design with marketing strategy is routine for most successful companies.”

not properly managed. Captive designers working within a manufacturing facility are usually skewed and pressured to design products based on the particular process conducted at their facility. Although this tendency is very understandable, it can result in designs that are ill suited for the process or completely inappropriate for the intended customer. Designers focused on rotational molding can often ignore cost advantages of alternative processes, critical features required by the market or important material property requirements. The resulting designs can prove to be too expensive, visually hideous or made from the wrong material. Good design requires

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Designing for the Customer


2012 StAR Conference Highlights A big success in Delhi! The StAR Rotomoulding Conference took place January 29-31 at the Crowne Plaza in New Delhi. The theme for this year’s conference was “Overhead to Underground…Rotate all Around”! “This was the best StAR Annual Conference yet including: a record attendance; 66% molder attendees; 40% of the delegates attending from outside India; global networking; a gala night full of fun and frolic; genuine excitement and a conference abuzz at all times; and all was supported by 15 world class speakers! It was indeed satisfying!,” said Ravi Mehra, Conference & Program Chairman.

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The Conference and Program Chairman, Ravi Mehra, opened the meeting with a warm welcome. “Design, materials, process, tank standards and underground tanks are the primary focus and value for the program,” he said. “But, don’t forget, the greatest value and opportunity at these conferences comes from networking and building contacts and gaining knowledge from each other,” Mehra added. Prior to the conference presentations, two education seminars were offered including “An Introduction to In-Process Rotational Foam Moulding”, led by R. Dru Laws, Seljan Company, USA. Law’s seminar provided an introduction to in-process foaming, an overview of how rotomoulding a skin affects in-process foaming; an in-depth look at the drop-box foaming method; an in-depth look at the fill-port foaming method; an in-depth look at the one-step foaming method; an in depth look at the foam-bag foaming method; and tying it all together. The second seminar was on Designing Rotomoulded Underground Hollow Chambers, led by Mike Paloian, IDSYS, USA. Paloian’s seminar included a review of regulatory considerations, general specifications, suggested practices and structural considerations pertaining to the design of underground tanks; manholes and other hollow chambers which can be rotationally molded. Factors discussed included: costs, installation considerations, structural requirements, soil conditions, environmental factors and material selection. Design parameters included

Ravi Mehra, Conference & Program Chairman

Puneet Madan, Reliance Industries

suggested details for attaching pipes, covers, and other features, which affect overall performance. There was also a discussion on long-term creep, oxidation and chemical resistance included. Starting off an impressive lineup of presentations, Puneet Madan, Reliance Industries, India, covered the future of the Indian Rotational Moulding industry. “Of the global 2011 PE Market, Roto was 1.6%, which has grown significantly over the past few years. The expectation is that by 2016 Roto will have grown faster than average compared to trends in the rest of the world,” Madan said. He outlined a vibrant capital market with booming infrastructure, expanding consumer markets and a change in lifestyle as part of the Indian growth story. “PE consumption in 2009-2010 was 4% Roto, and the Indian Rotomoulding Market shows steady growth, despite a few hiccups,” he said. “In 201112, 72% of production was tanks with 28% in other products,” he said. Madan reported on opportunities for rotomoulding in the areas of water management, agriculture, infrastructure and traffic safety. “Opportunities lie in improving efficiencies in product design, energy, managing skill sets and installation protocols and services,” Madan said. Ian Hansen, Bushmans, Australia, presented a moulders’ Guide to meeting tank standards. “The aim of the Guide is to give moulders a better understanding of technical data sheets given to them by material suppliers. This includes data that

Ian Hansen, Bushmans Australia

Dhanu Patell and Shivinder Chawla, Reinhardt, receiving appreciation award - presented by Ravi Mehra and Swetang Dave.

JANUARY-FEBRUARY 2012 • Rotoworld®

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Ashish Baheti and Ravi Mehra

StAR Dancers

Swetang Dave, StAR Incoming President

Aldo Quaratino, Matrix Polymers

The StAR Gala Band

Mukesh Ambani, StAR Outgoing President


Dr. Jitendra Kapadia, BASF, India

StAR attendees at Gala party

Ian Hansen, Australia, and Chandu Shah, Kenya

Bhavin Vasavada and the N.A. Roto Booth

Alain St. Pierre, Reduction Engineering & Rotoline, and M D Valecha, Gee Pee Nigeria

Rickshaw “ ride “ at StAR Gala party

Dr. and Mrs. Nick Henwood, 493K International

StAR Luncheon

StAR attendees at Gala party!

Swetang Dave, Consta Cool, and Satish Gokhale, Design Directions

Shivinder Chawla, Reinhardt, and Dr. Jitendra Kapaida, BASF

The Shuklas, father & son from MPlast

Satish Gokhale, Design Directions India

Lal Singh, Fixopan

Jessica and Dru Laws celebrate anniversary at StAR Conference.

many polymer suppliers don’t provide in their tank grade data sheets, including longterm data, even when they have it available,” he said. Hansen reported that the inability of users to compare technical data from different suppliers could assist moulders in getting reluctant polymer suppliers to move towards standardization. Bushmans made the decision to obtain Product Certification relatively recently because of commercial pressures, brought about by the rapid growth in the new tank moulders into the market and an increase in consumer complaints of poor quality,” he said. Celal Beysel, Floteks A.S. gave a very interesting talk on rotomoulding product development and innovation. Celal covered various types of innovations, which ones best suit rotomoulders and why rotomoulders need product development and innovation. Providing examples of product development and innovation at Floteks, he highlighted the company’s development of manholes for infrastructure. “You need to have a core business supporting the investment of product development, and you have to be able to risk some of your resources to make it happen,” he said. “The most important virtue an average rotomoulder can have is the ability to be an entrepreneur who can innovate,” he said. Dru Laws, Seljan Company, talked about process control in the rotomoulding machine, which he says is “the key to growth in the industry”. If it can’t be accurately measured, it can’t be effectively improved, and, when performance is measured and recorded the rate of the improvement increases, according

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Rotoworld® • JANUARY-FEBRUARY 2012

Dru Laws, Seljan Company

Mukesh Ambani, Infra Industries Ltd.

Celal Beysel, Floteks, Turkey

to Laws. Rotomoulding process control started in the 70s with the advent of the “Squirrel” and then in the 1990s with the Rotolog, developed by Professor Roy Crawford and Dr. Paul Nugent. “Several systems exist today, and the differences between moulders who do and those who do not utilize these control systems are often obvious,” Laws said. S. B. Zaman, Executive Secretary, StAR, & Swetang Dave, Consta Cool, Ahmedabad, spoke on behalf of the Association. “StAR has achieved steady success and progress. It is of sound financial health, continually introducing new activities and now has an average of 60 members,” reported Zaman. During 2011, StAR hosted meets in Kolkata and Kathmandu. Swetang Dave, the incoming StAR President, told the group his focus would be on maintaining quality membership services and working hard to bring new rotomoulders into the organization for increased quality control and industry development. Aldo Quarantino, Matrix, UK, reported on a study about multi-layer applications, detailing applications such as the motorbike fuel tanks, snow mobile fuel tanks and boats. He talked about how much reduction in weight is achievable by selecting a stiffer grade (super linear) material and optimizing a multi-layer system. The study was conducted with Nottingham Trent University in the UK. “In the kayak and boating industry, it is well known how important it is to increase the

stiffness of the product without increasing the shot-weight and compromising quality,” he said. Drs. Gareth McDowell and Nick Henwood, 493K International, talked about cooling as the final frontier in rotomoulding process control. “Cooling is the single most varying factor in the entire rotomoulding process,” said McDowell. Cooling affects part quality, and the best cooling strategy is to apply a gentler cooling in a more controlled fashion to the entire cycle by cooling the air first, not the mould. Presenting the features and benefits of the company’s innovation KKool, they advocated taking control of cooling rates, achieving predictable shrinkage and adjusting mechanical properties. Satish Gokhale, Design Directions, India, introduced a new design – KT Weir Micro Irrigation Dams. “The government of India puts a lot of investment into building micro dams so the farmers can get water for irrigation posts during the monsoon season and until the onset of the next rains,” Gokhale said. The new rotomolded product replaces a heavy and cumbersome gate that has to be removed and reinstalled before and after the rainy season. The traditional gates have been regularly stolen as they have a good resale value. The objective for the new rotational moulding version of the gate was to design the gates in a material which would last longer, be easier to install, have less resale value, remain affordable, would not look interesting or attractive and would instill confidence that the gates will

S.B. Zaman, StAR Executive Secretary

Gary Lategan, Rotosolutions

Dr. Gareth McDowell, 493 K Limited

work as desired. Bloys Rijkmans, ICO/Schulman, Asia Pacific talked about the overall cycle time and peak internal temperatures for optimum cure, which he said tends to dominate the discussions in rotomoulding. He outlined what primarily occurs in a moulding during the first part of the cycle when the powder lays down against the mould. Rijkman’s stressed the importance of getting conditions correct during this period. He covered the effect of the mould shape relative to the machine orientation and the effect of the diminishing powder pool on the distribution of the powder. Dr. Jitu Kapadia, BASF, India, covered various changes that have taken place in the rotomoulding industry in India. He showcased how the effective use of Additives and Colorants has helped rotomoulders improve their productivity and eliminate problems faced on the shop floor and in the field. “Some pigment related issues in rotomoulding are related to moisture and dispersion and compounding is a better approach than dry blending,” Kapadia said. “Processing conditions are often more critical to UV stability than UV grading itself, so do not over cook,” he said. C. Chiengsirisupawon, SCG, Thailand talked about the importance of long-term properties of Polyethylene and gave a general description including failure mechanisms and testing methods. He compared the long-term properties of various MDPE comonomers, e.g. butene, hexene, octene and their various applications.

Manju Merha accepts appreciation award on behalf of Ravi Mehra - presented by Rajendra Shukla and Swetang Dave.

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Kemp Kim, Cytec, Asiacompare technical data Pacific, talked about new sheets and determine stabaliser solutions for what information is rotational moulding. “While missing. “There is no rotational molding light common standard within stability has been a topic the rotational moulding of discussion over the last industry on how technical several decades and the data sheets are presented process is easy and simple, to moulders,” Hansen said. it is difficult to control “The lack of standardization processing,” he said. “The means moulders will find it balance of UV durability and difficult to compare material thermal stability is the key property values presented to mechanical properties,” by their suppliers,” he said. he added. Cytec was led by Mike Paloian, Integrated longer durability requirements Design Systems, USA, and a growing interest in the talked about the essentials rotational molding industry of design as well as what to adopt broad processing makes design successful. He window technology to develop covered the considerations and launch a variety series and methods for developing of light stabilizers. “This can a successful product provide superior UV stability design and stressed the compared to current state of importance of defining art light stabilizers and broad product specifications processing window to have and applications. Paloian high thermal stability during discussed the importance process,” he said. of knowledge of materials, Richard Levesque, Ingenia, processing methods and Mukesh Ambani receives outgoing President’s award presented by Rajendra USA, gave an enlightening comparative costs as well Mukesh Ambani and Shukla Shukla. case history on metal as appropriate testing inserts and blow holes and evaluation processes. trouble shooting. Levesque “These are the basics of described the fundamentals good design,” he said. of the rotomoulding process, Several workshops were e.g. the thermal expansion presented including: What of gases, insert design, is your problem / Question? mold design, bridging, gas (Gary Lategan, N. Henwood, formation, sintering and most B. Costabir); Roto Grades importantly, provided some – MATERIALS – Q&A (Ian solutions to rotomolding metal inserts. He demonstrated Hansen, B. Riijkmans, A. Quaratino, SC, V. Kumar); Processing how blow holes appear and where they generally occur. “It & Process Control (D. Laws, G. McDowel and S. Dave); and becomes a major problem when a blow hole connects the Underground Tanks /Chambers (M. Paloian, C. Beysel and A. inside to the outside, causing a leak,” he said. Baheti). Gary Lategan, Rotosolutions, S. Africa, said, “We are always Social networking was a big highlight for the conference presented with choices concerning Machines, Materials and including an opening reception and dinner along with an Moulds, but too often we are drawn in by glossy brochures Annual Gala Dinner with the theme of a “Traditional Street and the “bigger vs. better” scenario. Now is the time to get Party in India”. The night included featured traditional Indian smart,” he said. “Other processors are becoming a threat dance music and costume entertainment along with traditional plus your competition is always working to get ahead in a “street fare” Indian food stations. The event proved quite competitive market,” he said. The benefits of simple, but festive and entertaining. smart rotomoulding is consistent quality, reduced scrap, A big thank you goes to the 2012 StAR Conference improved output and increased profit,” he added. sponsors who made the event possible: Reinhardt Roto Ian Hansesn, Bushmans Australia, also presented a Machines (Principal Sponsor); Reliance Industries and N.A. materials properties guide, which reviewed 14 material Roto (Platinum Sponsors); M Plast and BD Industries (Gold properties. He talked about how the moulder creates a Sponsors); and Baheti Rotoplast and Ideal Polytecnologies shortlist of materials to evaluate and how they should Infra Industries (Networking Reception Sponsors).

Social networking was a big highlight for the conference including an opening reception and dinner along with an Annual Gala Dinner with the theme of a ‘Traditional Street Party in India’.

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When mixing gothic, rotational moulding and bright colours together, you don’t really expect to think of modern design. Studio Job, a Belgium design studio, pioneered by Job Smeets and Nynke Tynagel, has taken rotational moulding back to the 16th Century with a touch of modern class. “We found a magnificent 16th-century Neo-Gothic chair in an antique shop and put it on the table at Moooi, proposing that this complex handcrafted archetype be produced by the industrial method of rotational moulding,” according to Studio Job. The design had to meet Moooi’s Contemporary design style and had to be readily sellable on a consumer level (like other Moooi products). To meet the requirements, the chairs were designed from the ground up to utilize the benefits of rotational moulding, and also encompass its limitations. The Gothic nature of the design is shown through the buttons around both the seat and the back support of the chair. Studio job drew up a design that acknowledged all the limitations of

Studio Job’s Neo-Gothic chair design

rotational moulding without sacrificing the character of the original model. The ‘gothic chair’ was born lucky right from the beginning. An affordable and functional archetype for indoors and out, available in a bright spectrum of ten colors, according to Job Smeets. The Gothic Chairs now sell via the internet (for approx. $348 US) and are available in 10 different colours. The chairs come with a small instruction manual mentioning a few key facts

about the storage and the cleaning of the products. The chairs have also been approved for Level 2 applications according to EN15373:2007 and subsequently are able to be used in hotels, homes and as public seating. The Chairs have been featured as various museum pieces, the current and largest showing of Studio Job designs can be found at the Groninger Museum in the Netherlands. The studio began when Job Smeets finished his course at the Design Academy in Eindhoven. 2 years later, when Nynke Tynagel graduated, the venture turned into a partnership. The design world was then confronted by two of their most recognized pieces; Cabinet (1999) and Craft(2001). Since their beginning, the duo have been both nominated and awarded many times at a national and international level and now continue to strive further with their ideas. Studio Job has had a plethora of clients including Swarovski, Balgari, L’Oreal and now Moooi with their newest piece. january-february 2012 • Rotoworld®

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the cutting edge

Studio Job’s Gothic Revival For Rotomoulding


2011 ARM Hall of Fame Inductees Jim Leitz & Daven Claerbout

The Association of Rotational Molders (ARM) honored Jim Letiz of Gregstom Corporation, Woburn, MA, and Daven Claerbout of Dutchland Plastics, Oostburg, WI, as the 2011 inductees into the ARM Rotational Molding Hall of Fame. The award, which is the highest honor the Association bestows on an individual for outstanding service, accomplishments and contributions to further the growth of the rotational molding industry, is dedicated to the recognition of rotational molders, suppliers and professional members. The 2011 award was presented during the 2011 Rotoplas and ARM Fall Meeting held in Chicago. Jim Leitz “It is a great honor to be recognized by one’s peers, and to be included in the company of the past honorees is quite a privilege,” Jim Leitz said during his acceptance speech for the coveted award. “In looking back over my involvement with the Association, three things have stood out,” he said.

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First, “I have grown personally through the relationships formed with those I’ve worked with in the ARM organization. The camaraderie and interaction with other members, staff and fellow officers has been very rewarding,” he said. Secondly, I have grown professionally as there has never been an ARM meeting I’ve attended at which I didn’t learn something that would help me improve myself, or my rotomolding operation. There was always one little technique or cost savings idea, which I picked up at one of the presentations, or informally in conversation, that would pay for the cost of attending the entire ARM meeting,” he said. And, finally, “I hope my involvement as a committee member, board member and as president, has contributed to the improvement and success of the Association, and therefore to the rotomolding industry as a whole,” he said. Jim ended his acceptance speech with a challenge to the new, young and older members alike to become involved in the Association.

“Get involved in the Association. You will benefit personally, professionally and your involvement will help to improve the rotomolding community as a whole,” he said. Scott Saxman, Mold In Graphic Systems, said “After joining Mold In Graphic Systems® in the Summer of 1991, I had the very good fortune of making the acquaintance of Jim Leitz at my very first ARM conference, which was held in Chicago later that same year. This fortuitous meeting was the beginning of a valued professional and personal relationship, which has lasted over 20 years. Working closely with Jim over these many years has provided me with a close-up understanding and appreciation of his sharp business acumen and professional approach in his position with the Gregstrom Corporation; skills that have helped make their company into a well-respected Rotational Molding organization. Jim’s many years of dedication and service in many capacities with ARM are much admired and appreciated by all of us in the Association and greater industry as a whole. On behalf of so many of us who have benefitted from these efforts, congratulations on induction into the ARM Hall of Fame. It is much deserved”! Michael Paloian, Intergrated Design Systems, said, “In my opinion this recognition was well deserved and far overdue. Jim is one of those rare individuals who possesses a number of distinctive qualities that set him apart. He is a generous and highly intelligent individual who conducts business with integrity and honesty. His extremely modest persona obscures his in-depth knowledge of rotational molding on multiple levels.” Celal Beysel, Floteks, Turkey, said, “Years ago we hosted Jim and his wife Kathy in our home town, Bursa, Turkey. We were very happy to have them as guests, and as a rotomolder, I was excited to have one the most experienced rotomolders in the US in my factory, which at the time I was trying to modernize. I’ve discovered that Jim’s biggest virtue isn’t rotomolding, but it is his sense of humor and joy of life, which he passes to everybody around. He is the guy you want to be friends with!” Jim received his BA at Williams College in 1965 and completed post-graduate work at Northeastern University. He started his career in plastics at Mack Molding, an injection molding company, in 1965. Jim joined Celanese Plastics, a film and sheet molding company, in 1968, and then began his career in Rotational Molding in 1973 when he and his father co-owned Bayhead Products in Dover, New Hampshire for ten years. Jim joined Gregstrom Corporation in 1989 as the Vice President of Marketing. He set up and developed the Gregstrom Corporation Rotational Molding division where he is currently Vice President Rotational Molding. Jim’s mantra as ARM President was for the Association to remain focused on the “value ARM provides its members”. In addition, his goal in moving the organization forward was to “make ARM a strong, active, member-driven organization of molders and suppliers who can start addressing the challenges

ahead. ARM involvement for Jim, over the years, has included serving on various committees including: Rotoplas, Polyolefin, Forums and Programs, Trade Show and Membership. He served on the ARM Board of Directors from 1999 – 2004 including holding the positions of Board Member, Secretary/ Treasurer, Vice President and President (2001-2002). By taking on the role of ARM President immediately after September 11, 2001, and due to travel bans after 9/11, Jim was at the healm when meetings had to be cancelled and rescheduled and convention halls and hotel contracts had to be renegotiated. Once the airlines started operating again many companies still would not allow employees travel by air, therefore, Rotoplas was cancelled and moved from Minneapolis in the fall of 2001 to Toronto in the spring of 2002. It was during Jim’s term that the second change in ARM organization management structure was implemented. “It was apparent in 2000 and 2001 that there needed to be a change in the management of the ARM organization after many years. We had to establish a search committee and hire a new executive director and almost completely new staff,” he said. Jim worked with new and existing staff during a difficult transition period.

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Daven said he was grateful to the members for accepting his kind of leadership, which is of a more of a lighthearted nature, and he said as an example, a bet was on for whether he would go over or under his time limit for his acceptance speech. His brother Carl was the bookie! Daven has strongly promoted membership throughout his leadership roles in ARM. He is a strong proponent for Association membership and once said, “Without making the decision to become involved and attend meetings, I know my knowledge of rotomolding would be limited to what I learn here daily on a trial and error basis.” Daven served on the board when some of the hard and emotional decisions concerning executive management were made. “I would like to take some of the credit for signing the best free agents we have ever had, specifically CM Services, Daven Claerbout is presented the ARM Hall of Fame Award by Bill Spenceley, ARM VP. Rick Church and the whole family. Also during Jim’s term as ARM President, he began the You are absolutely rock stars and we just love what you’ve development of the International reorganization of ARM. He done with the Association,” he said. worked with the International Rotomolding organizations to try Daven gave thanks and appreciation to Dutchland’s to establish an “umbrella organization” to coordinate activities employees. “They are really the people responsible for me of all Rotomolding organizations worldwide. Meetings were getting this award. Carl and I are the luckiest people in the held with all international groups in Paris, Munich, Brussels world to have over 200 outstanding employees at Dutchland,” and the US. “Our work at that time served as a basis for the he said. Daven recognized Dutchland employees present future development,” he said. for the award including: Eric Brill (Sales Director); Jeff Van Jim and his wife Kathie have been married since 1965 and Straten (President); Tom Wood (Sales Rep); April Dowland (HR have two sons and a daughter (deceased in 2005) and nine Director); Mike DeHaai (V.P. Operations); Tracey Brill (Project grandchildren. Manager); and Tedd Mentink (Director of Engineering). Daven recognized his children who are also employed at Dutchland. Daven Claerbout “I am particularly lucky that I get to work with my children, “This is a really neat honor and I was trying to figure out what Lindee, Billy and my daughter-in-law Niki. He paid special would start the night out perfect when the phone rang. It tribute to his brother and partner, Carl Claerbout: “Carl is was my son Billy, who is named after our dad, who asked if the one who should have served on the ARM Board. I am the he could come down and have me help him tie his tie. This more outspoken of the two and he is the more quiet. If you reminded me of my dad who has tied Carl and my ties so many ever wanted a partner in business or personal life, you won’t times, and I realized that Dad is still here with us,” Daven said find a better person than Carl Claerbout.” during his acceptance speech. Daven closed with this thought, “You never know who “I am not here to talk about myself, but rather the people you are talking to. “John Hammond, general manager of The that have made it possible for me to receive this award,” Milwaukee Bucks and former general manager of the Detroit Daven said. He paid special tribute to his mother, Nancy Pistons, visited our plant and said, “Joe Dumars, president Claerbout. “She has always had great intuition for our of the Detroit Pistons once said, “I don’t judge a man by how business. She has a tremendous business sense and a great he treats me, I judge him according to how he treats the next love for her employees and especially for her two sons running person after me. the business,” he said. “We love you Mom. We miss dad, but Daven continued his leadership role by challenging people we are so glad you are still here for us,” he added. to get involved and become part of the Association. “We’ve

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learned so many things from our involvement in ARM. We are so blessed and I want everyone to get involved and be part of it,” he said. Friend and colleague George Winter, H. Muehlstein & Co., commented about Daven: “I have had the extreme pleasure of knowing and working with Daven Claerbout for quite a few years. No one would ever say Daven is a ‘wall flower’. His charisma and outgoing personality make him someone people gravitate toward. I got to know Daven while serving on the ARM board. Daven’s optimism and vision helped steer ARM back from some lean years. The organization is solid again, with much credit due to Daven’s leadership. Spend a little time with Daven and it’s easy to see where he comes from (and I don’t mean Oostburg). From his mom and dad (whom he quotes often), he’s developed a strong work ethic, a habit of giving back to the community and a strong belief in family. While I’ve been fortunate that our professional relationship has grown into a business one with Dutchland Plastics, I, along with my family, have been most fortunate to have been welcomed, included and warmly received by Daven and the Claerbout family. (Now, if he could only root for a baseball team I didn’t hate, we’d be okay.)” Co-worker Tracey Brill had this to say about Daven: “It was an honor to attend the awards ceremony when Daven was inducted into the ARM Hall of Fame. It is a well deserved

recognition for a man who truly cares about this association and its future. During his speech, that went under, he gave credit for his success to his family and employees of Dutchland Plastics. It is no secret that every successful company requires great leadership and Daven along with the Claerbout family have done all they can to make Dutchland Plastics a leader in this business. With Jim Leitz and Daven inducted into the ARM Hall of Fame, two very deserving gentlemen are recognized for their personal contributions to ARM.” Daven started in rotomolding at age 9 when he hung out at the company his parents owned after school. At 16 years of age, he began working on machines in the plant, which continued throughout high school and college. In 1984, he returned to company and has been there ever since. Daven is Executive Vice President of Sales and Co-Owner of Dutchland Plastics, the company started by his parents Bill and Nancy Claerbout in 1967, along with his brother Carl Claerbout. Daven has served on the ARM Board for 10 of the past 11 years. He has served the organization on the Environmental, Membership and Forums & Programs Committees, as Secretary, twice as Vice President and twice as President. He currently serving his second term as Past President. Dutchland has been the recipient of several product awards as well as the Organizational Service Award.

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ARMA (Association of Rotational Moulders Australasia Inc.)

Letter from the ARMO Chair (2010-2012) 2012 is ramping up to be a busy year for ARMO, continuing the momentum of the very successful Rotoplas in Chicago last November! The recent conferences in India (StAR) and Sweden (Nordic-ARM) were great successes and continue to see attendance grow! There is strong support for our other partner association conferences with discounts available to rotomolders worldwide. Of course the big ARMO event of 2012 will be the Lyon Conference being held September 30th to October 2nd. I’m very excited that this meeting will also be the first major rotomolding event to be hosted in Europe since the successful Belfast meeting 4 years ago. Attendance is expected to be the largest yet and I would suggest that you consider joining our French host organization (AFR) in Lyon. This year’s program is still in development but there is already a strong line up of presentations from world experts in the industry. The deadline for presentations is February 29th so I would strongly suggest you visit the ARMO website for more information. Mark those dates on your travel calendar. This is also my last year as the face of ARMO and I want to welcome the next Chair, Mr. Ravi Mehra who will serve the alliance 2012-2014. For many years, Ravi has been a strong advocate of global cooperation in our industry and I believe he will have a positive influence. His term begins in Lyon but there are a number of projects I will see to completion before I hand over the reins. ARMO will continue to develop our website with more content. In addition we are assembling a resource library online for the benefit of active ARMO partner association members. This library will have proceedings from the past Pan European Conferences (PEC), ARMO events (including Belfast), as well as technical papers from our newsletters. ARMO will continue to coordinate with the other partner associations on industry standards and shared research projects. We may also see some new member associations join the alliance as the industry continues to grow. I encourage all of you to keep visiting our website, view the progress being made and continue to enjoy our informative newsletters. Best of luck to you all in 2012!

RotoTour 2012 Takes off to Poland and France!

The Association of Rotational Moulders Australasia is excited to be able to offer a unique opportunity to rotational moulders from around the world. Following the huge success of the USA, China and European Plant Tours, ARMA has negotiated with nine rotational moulding factories to allow a group of delegates to tour their plants. During the tour, there will also be a visit to a powder supplier and a local University to expand on the range of insight the tour will provide. In addition to the business aspect of the tour, delegates will have the chance to enjoy some incredible travel experiences and attendance at the ARMO Conference and Tradeshow in Lyon, France. One of the major benefits for delegates on the tour will be the chance to develop great relationships with the other participants, whom you can keep contact with long after the tour has concluded. But act quickly, there are only limited places available and the tour cannot be extended. The opportunity to visit rotational moulding factories on the other side of the world, build friendships and partnerships with companies involved and to attend the ARMO Conference and tradeshow in Lyon is one you just can’t miss. But register quickly as there are only limited places.

Sincerely, Bill Spenceley ARMO Chair 2010-2012

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ARMO Conference – Lyon France The ARMO Convention format is based on its previous successes in Berlin, Rome, Paris, Brussels and Belfast. The Convention is now internationally recognised as the event not to be missed in the rotational moulding industry. During the twoday event, ARMO 2012 will be welcoming guest speakers recognised in the sector. As with the previous events, the presentations will be translated simultaneously in English, French, German and Italian giving delegates a unique opportunity to hear presentations not normally available to them. The conference registration is included in your tour cost and there is an opportunity to register for an Optional Workshop - Rotomoulding Training Seminar on Sunday September 30. For more details on the conference, go to The Factories Rototour has been honoured by the opportunity to visit the following plants in Poland: Kingspan Environmental – Kingspan Environmental is part of the international Kingspan Group. A wide product range of the Titan, Roug and Klargester brands sets industrial standards for safe storage of such products as heating oil, diesel fuel, biofuel, chemical substances, stormwater, consumptive water, AdBlue® and foodstuffs as well as for selective collection of municipal waste. Promens Miedzyrzecz – Promens Miedzyrzecz was founded in 2001 under the name Bonar Plastics Polska, but acquired by Promens in 2005. The company manufactures rotational moulding products for material handling as well as custom moulded parts, for a wide range of customers. Among key products of Promens Miedzyrzecz are customised products for automotive, agriculture, water treatment and other industry.

Krakow, Poland

Sunday 23rd September Arrive Krakow Welcome Dinner

Monday 24th September Group Breakfast Tour of ERG Systems Lunch Tour of Orex Tour of Elplast Group Dinner Accommodation

Tuesday 25th September Group Breakfast Factory Tour (TBC) Coach to Poznan Group Dinner Accommodation

Wednesday 26th September Group Breakfast HABA Tour Lunch Poznan University Sightseeing Group Dinner Accommodation

Thursday 27th September Group Breakfast Kingspan Tour Promens Tour Lunch Group Dinner Accommodation

Friday 28th September Group Breakfast Matrix Polymers Tour Lunch Form Plastics Tour Sightseeing Group Dinner Accommodation

Saturday 29th September Group Breakfast Flight to Lyon Group Dinner Accommodation

Sunday 30th September Free Day or Optional Workshop Group Dinner Accommodation

Monday 1st October Group Breakfast ARMO Conference Conference Dinner Accommodation

Tuesday 2nd October ARMO Conference

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FORM-PASTIC – Form-Plastic is a company with traditions producing a whole range of garden products which has operated for over 30 years. It was founded in Ciechocinek, a gem of spas in central Poland, by Mr. Andrzej Waldowski. In time, this small firm producing for the local market developed into a large company supplying its products to half of Europe and much of Asia. The “Crazy Flower” sprinkler, one of the first hits of FORMPASTIC, has become so popular at home and abroad that it is now a classic in this type of design. Elplast – Elplast is a private company, 100% Polish family owned, that deals in the production of polyethylene and polypropylene pipes and profiles by extrusion moulding and also large-size and small-size polyethylene products by rotational moulding. They employ approximately 160 staff and also have their own in-house testing laboratories. Orex – Orex was founded in 1989 and its first step into rotational moulding was in 1995 by building first carousel machine to produce elements of balcony balustrades and fence boards. Experience has allowed Orex to produce quality, simple, cheap and reliable products. They also have experience in the scope of steel and aluminium moulds production. With over 17 years’ experience, HABA produce a wide variety of waste water treatment options. Their motto is the production of energy-efficient, reliable and friendly waste water treatment options, which fit in with the surrounding environment.











Poznan University – Based on Poznan University, Dr. Szostak is a professor specializing in rotomoulding, he is also the President of “Rotopol” organization (regrouping Polish moulders). **Factories may be subject to change. ARMA will make every effort to replace any cancellations with similar factories in areas that work with the tour itinerary. The Countries The tour is includes an action packed program but it isn’t all hard work. Poland is an incredible country with a rich heritage and lots of opportunities for tourism. History and local flavour will be an integral part of the tour, but we have included some of the highlights to give you the flavour of Poland and what you will see during the tour! City Of Poznan Tour with Local Guide Poznan is widely acclaimed as a business or trade fairs city. It is quite probable that you come for business and get keen on learning more. Our tour starts on the island of Ostrow Tumski, the most important royal residence during the days when Poland was still a pagan country. This is where you will find Poland’s very first cathedral: St. Peter and Paul’s (as

Pope John Paul II used to say: “This is where Poland started”). From there we will take you to the charming Old Town of Poznan, where you will see the hallmark of the city, the “Poznanskie Koziolki”: two charming billy-goats that butt heads every day at noon. While in the Old Town you will have time to admire the Old Town Square with its Renaissance Town Hall. From there you will stroll through the narrow streets of this historical area until you reach St. Stanislav’s Church (also known as “fara”), a precious pearl of the Polish Baroque, brimming with gilded ornaments and mouldings. Free Time in Gniezno Rated as one of the oldest towns in Poland, Gniezno maintains a unique place on the country’s map. Nearly all of historic buildings within its walls can trace their origins to the earliest period of the Polish state. Recently a number of these buildings have been renovated, helping to revive the visible historic importance of the town in Poland. Gniezno is also recognised as a significant place of worship of Saint Adalbert, the first bishop of Prague. The single most un-missable thing to see in Gniezno is the 14th-century Gothic Cathedral, with its priceless memorabilia, relics and the tomb of Saint Adalbert that draws Catholics from all over Europe. The Cathedral

ERG Systems – ERG Systems produce a range of products including crates and pallets. Matrix Polymers – Since Matrix was founded in 1992 they have grown to become one of the leading suppliers of raw materials to the rotomoulding industry. Poznan, Poland

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witnessed the coronation of the first five Polish kings, and one can also visit the archive containing several of Poland’s earliest manuscripts. There are also several Gothic churches to see in this history-laden town and the Archdiocesan Museum and the Museum of the Origins of the Polish State are well worth a visit. Lyon, France Lyon is between two hills, the Fourvière and Croix-Rousse and between two rivers: the turbulent Rhône and the tranquil Saône. Lyon is a very industrial city, textile manufacturing is one of the most important here. But not only that, this city is known as the capital of gastronomy, like Paris, this city has the largest number of Michelin-star restaurants. The most famous chef, Paul Bocuse, has his restaurant in Lyon. Lyon is also called the ‘city of light’ because of its history which began on Fourvière Hill, when the city was under the Romans. The city was proclaimed capital of the three Gauls and it was during this period that Lyon developed in economic, politic, religious and military terms. The Hotels All accommodation during the tour is included in the price and we have sourced a great range of mid-priced corporate hotels to lay your head at the end of our long tour days! The stylish Holiday Inn Kraków City Centre hotel is conveniently located in the heart of Kraków’s Old City, only minutes away from the main Market Square, Kazimierz Jewish Quarter, Wawel Castle, the central train station and bus terminal, and Kraków’s biggest shopping centres. The luxury hotel itself is a unique architectural blend of a 19th century palace encompassed by modern buildings. The hotel offers an underground garage, a business centre, a mini gym and massage room. High speed Internet access is available free of charge in all rooms and a wireless connection can be established in all











common areas. Mercure Ostrava Center is a brand new 4 star hotel in the city centre of Ostrava with a restaurant, bar, summer terrace, fitness area with a steam bath and the hotel is within walking distance to the cultural and commercial districts of the city as well as the famous “Stodolni” street. Rooms come with individual air conditioning, bathroom with shower or bathtub, working area, tea and coffee facilities, hairdryer, minibar, laptop-size safe, free internet access and LCD TV. The Novotel Poznan Centrum is situated in the city centre, 500 m from the train station, opposite the Old Brewery, near the Old Town and the Poznan International Fair. The hotel has air-conditioned rooms with free Internet access and satellite TV. It also boasts a restaurant serving regional and international dishes. The Hôtel Ibis Part Dieu Gare is only 10 minutes from the International City, close to the Gare Lyon Part Dieu and the largest shopping centre in Europe, you can easily access the city centre from here too. The hotel offers an authentic restoration around the fireplace. WIFI is available throughout the hotel even in the rooms. All rooms are soundproofed and air conditioned in a modern atmosphere. The conference is being held close by the hotel venue. Registration Includes • Full ARMO Conference Registration (Full Delegates Only) • Gala Dinner Tickets & All Conference Meals • All Domestic & Your Poland – Lyon Flight throughout the tour • All Accommodation during the Tour in Quality Hotels • All Group Meals during the Tour • All Private Tours and Transfers during the Tour • Beer, Wine & Soft Drinks with Lunch & Dinner • Private Tour Guides • All Factory Tours during the Tour • Airport Transfers during the Tour Only • Special Registration Pack

Does Not Include International Flights to Krakow and from Lyon International Airport Transfers Travel Insurance Visa Application Fees Alcohol (other than provided at meals) Terms & Conditions ARMA has been able to arrange these exclusive tours with the support of the Alliance of Rotational Moulding Organisations. The companies who have approved tours of their plants and facilities have done so according to certain conditions, which you must indicate you are willing to agree to abide by, before your participation can be confirmed. If the tour is cancelled or postponed for any reason beyond the control of ARMA, all efforts will be made to schedule the tour for a later time. Refunds are subject to the approval of the ARMA Board on request, however no refunds will be offered for cancellations one month or less prior to the departure of the tour. By completing the registration form and lodging it with the Association, you agree: • No Cameras, Mobile Phones or Other Electronic Devices Allowed In the Plants • No Delegates with Business Interests in Poland Allowed • No Conversations with Plant Staff during the Tour Unless Approved • You Must Attend All Tours, No Special Arrangements Will Be Made • Registration Is Subject To Availability on A First Booking Basis with Preference to ARMO Members • Partners Registration May Be Subject To Availability To register or for more information go to and look in the “Events” tab or email Places are limited! Early bird discounts end on 20th April and registrations close on 30th August or when all tickets are sold. january-february 2012 • Rotoworld®

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StAR (Society of Asian Rotomoulders)

2012 StAR Product of the Year Competition Good Engineering & Design Come to the Fore

StAR Product-of–the-year2012 - Pressurising Machine Housing

▲ R K Sethi, owner of Maharashtra Maha Polyplast, receiving winner’s-trophy – presented by Ravi Mehra and Swetang Dave

StAR held its 2nd ever Product–of-the-Year competition at its recent 2012 annual rotomoulding conference in New Delhi, Jan 29 – 31. The previous competition was held in 2010. StAR Product-of–the–Year–2012, selected by an international panel of judges, is the Pressurized Machine Housing submitted by Maharashtra Maha Polyplast of Mumbai. It has been tooled-up and manufactured for a customer in Europe. This housing maintains water under pressure and consists of three rotomolded parts: Main Body, Water Tank and the Base Pallet. The main Body has a number of moulded in metal inserts for the easy installation

of the pump and mounting of the PLC control panel. The product design has been produced using 3D modelling and the moulds are CNC machined in steel. Attractive aesthetics have been ensured by no visible parting lines. Material is an imported grade of LLDPE pre-coloured and UV stabilized. The 2012 StAR Product of the Year Competition was a step forward in terms of the type and quality of products which are being produced in the StAR India general membership region.

The remaining entries included:

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Wave bench submitted by Frontier Polymers - is a highly attractive modern indoor/outdoor furniture design, very versatile in use, colours and finishes. Cast aluminum fully etched mould has been used.














Fuel tank submitted by GMI Zarhak which is mounted on a portable concrete mixer. Its design features enhance storage capacity.

Mobile Solar Cooler Wagon Shop submitted by Maharashtra Maha Polyplast - A light weight vendor’s shop with double walled cooler body.

Panel of Judges: • Ravi Mehra, Norstar Int’l USA • Swetang Dave, Consta Cool India • R P Shukla, MPlast India • Dru Laws, Seljan Company USA • Mike Paloian, IDSYS USA • Celal Beysal, Floteks AS Turkey • Bloys Rijkmans, ICO Polymers Asia Pacific

▲ Water storage tank submitted by Himgiri Tanks - offers an attractive free flow design with pitcher shaped top. It is offered in many attractive colours.

Association of Rotational Moulders Australasia Inc. 1st Floor, 40 Ipswich City Mall, Ipswich Qld 4305 PO Box 826, Ipswich Qld 4305 Australia Phone: +61 (0)500 567 808 Fax: +61 (0)7 3009 0600 CEO: Leisa Donlan Deputy Executive Officer: Michelle Lorenzo

Federazione Gomma Plastica AISR - Italian Rotational Moulders Group Via San Vittore, 36 20123 Milano –ITALY Phone: +39 02 439281 Fax: +39 02 435432 President: Renzo Martini Group Executive: Enrico M. Chialchia Group Contact Person: Simona Tiburtini -

Association of Rotational Moulders Southern Africa PO Box 8184 Centurion South Africa, 0046 Phone: +2782 782 041 President: Clive Robertson Secretary Treasurer: Anle van Niekerk, Accelerate Design

The Nordic Association of Rotational Moulders Executive Board Chairman: Mr. Ronny Ervik ul. Zielona 8, 61-851 Poznan, Poland Phone: +48 607-126-004 Fax: +48 61-858-8611

Society of Asian Rotomoulders (StAR) 40/145, Ground Floor, Chittaranjan Park New Delhi-110019 Phone: + 91-11-41630157 Fax: +91-11-41634952 Mob: + 91- 9810305356;

Association of Rotational Moulding (Central Europe) e.V. (ARM-CE) MAUS GmbH - Rotationsgießformen Am Viehweg 9 - D-76229 Karlsruhe Amtsgericht Mannheim, HRB 103433 Tel.: +49-(0)721-94874-0 Fax: -44 Mr. Oliver Wandres, ARM-CE Chairman

The British Plastics Federation Rotamoulding Group 6 Bath Place Rivington Street London EC2A 3JE UNITED KINGDOM Phone: 020 7457 5000 Fax: 020 7457 5045 President: Allan Joyce Group Executive: Dhrupal Joshi

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Completely Wrong Yet Totally Right

N ot e s f r o m t h e r oa d

I was wrong. After working on a series of disputes and legal cases over the last few years, my latest seminar on how to ‘Avoid Legal Exposure in Rotomolding’ was aimed at attracting people interested in finding out how to minimize their risk by addressing key aspects of how they approach rotomolding. Instead I found that people were generally put-off by the word ‘legal’ in the title. It is amazing but given the litigious nature of modern society it clearly had a serious negative connotation and created a barrier to people even reading beyond the title. I learned that I need some help in the marketing department! Thankfully there were those that did look further than the headline and after seven outings (a mix of multi-company and in-house events for individual companies) the reviews have been good. Attendees loved the course and in many cases were genuinely surprised at the extent of the content. The intention (even when it was the full ‘legal’ version) was to address the process from beginning to end and identify the

good habits and practices that will help rotomolders avoid most problems from developing and even in situations when something does happen to leave them better prepared to deal with it. From examples of disputes to defining performance requirements, addressing basic contracts and agreements to good process control and from how to select materials based on product performance to good QC practices, there is a wealth of information for all levels. Even old-timers and seasoned shop-floor practitioners found it useful to be reminded of all the possibilities in the process and the little things that make a big difference. But I needed a new title. And so, in a classic case of rebranding, the new title is ‘Rotomolding – Doing It Right the First Time’ with a subheading of ‘and Avoiding Legal Problems as You Go’. The content has been sharpened by interaction with recent attendees and fine-tuned to address specific molder questions but the message remains the same: good practices and good

The fjords of Norway are spectacular – Slartibartfast won an award for them…

62 |

Rotoworld® • january-february 2012

habits produce good parts and prevent issues from arising. Funny to think that even when I was totally wrong, I was absolutely right…

runs a very nice operation – they also occupy arguably one of the most picturesque locations of any rotomolder in the world. The photograph above was taken from their storage yard! I hope to be back but maybe when there’s a little less snow on

Scandinavia Rising The recent ARM Nordic event in Stockholm reinforced the

the ground…

growth and interest in rotomolding in the region. Around 75 people gathered to hear a number of key suppliers deliver useful presentations with molder specific solutions and some thought provoking analyses. There was even a visit to local molder Wavin showcasing their approach on how to produce large technical products; along with their willingness to share ideas for the benefit of the industry at large. Some 55 of the attendees stayed an extra day (bleary eyed and hungover from excesses in the hotel bar) to hear yours-truly and the rebranded version of my seminar (see above). Most of them stayed awake – always a good sign – and I enjoyed the interaction. My compliments to Chairman Ronny Ervik on his hard work and determination to raise awareness for their members. And while Stockholm was chilly, the little tourist town of Molde on the coast in the middle of Norway proved almost balmy (at least above freezing for part of the day). The molder of Molde, Partnerplast, specializes in marine products and

Two Sides to the Coin

It may not apply to everyone but all the molders I’ve visited in the last couple of months in the USA have been exceptionally busy. Some are planning to add machines, some talking about new facilities and others looking at their lean activities to try and keep up with demand. Sounds strange? Certainly does given the backdrop of the election distraction and economic pundits, but who’s complaining. Long may it last and hopefully it comes to a molder near you. On the other hand, there are changes in the US industry again with closure of the remnants of what used to be one from multiple plants to zero in a few short years: lack of understanding by new management/ownership? Cannibalizing of the best parts of the business? Image deficiencies? Slow down in key markets? Who knows? Sad to see but it will be a bonus to some molders who will pick up new customers.


Rotationally Molded

Plastics Your Source for Any Plastic

Hollow Product Shape Up to (95" diameter) and No Matter How Intricate.


Toll Free Fax 1-888-779-3065 320 N. Clark, Dept. JT, El Paso, Texas 79905 International Calls: Tel 915-779-1405 Fax: 915-779-3618

january-february 2012 • Rotoworld®

| 63

N ot e s f r o m t h e r oa d

of the largest rotomolding companies. An amazing drop

RotoWorld® will launch a new website designed to grow the industry and expose your company and products before the world of rotational molding:


2012 Online RotoTradeTM Show

A New Way for the Rotational Molding Industry to Communicate • Product Showcase • Online RotoTradeTM Show • Online RotoMapTM • Worldwide Association News • World Calendar • Design & Rotational Molding • Product Conversion • Social Networking • Find a Rotomolder, Supplier, Designer, and/or Educator • Marketplace

JSJ Productions, Inc. | 14101 Highway 290 West, Bldg. 1600-B | Austin TX 78737 USA | 512.894.4106 | Fax: 512.858.0486

november-december 2011 • Rotoworld®

| 64


Large variety of moulds for planters and water tanks, for sale. Nice shapes - well kept. For more information, please contact Mr. Antonio Penta at

Vasta gamma di stampi per piante ornamentali e serbatoi, forme eleganti e piacevoli, in ottimo stato di manutenzione. Per maggiori informazioni contattare il sig. Antonio Penta a

Engineering Studies Design for Rotational Molding Cost Reduction Studies Scale/Full Size Models Finite Element Studies

Industrial Design Ergonomics Solid Works 2007/08 Marine Hull Designs Silicon Rubber Molds

Stanley Widmer Associates Inc. 1406 Prairie Ave. NW Unit A Staples, MN 56479 Ph/Fax 218-894-3466 • Cell 320-237-0062 •

Growing tool builder looking for a seasoned sales person to fill a sales position Please send your confidential resume to Vince Costello at Diversifed Molds via email to

Using the right bait makes all the difference. Advertise in

For more information call, 512.894.4106. Subscribe online at

JANUARY-FEBRUARY 2012 • Rotoworld®

| 65

w o r l d ma r k e t pla c e



68 ExxonMobil Chemical Co.

7 Mold In Graphic Systems®

223 - 8171 Yonge St. Thornhill, Ontario Canada, L3T 2C6 800.668.0177

5 Ferry Industries, Inc.

4445 Allen Rd. Stow OH 44224-1093 USA 330.920.9200

999 Highway 89A

PO Box 1650

Clarkdale AZ 86324-1650 USA


63 Niland Co.

320 North Clark

El Paso TX 79905 USA

800.648.9013 915.779.1405

21 Gerbaldo Polimeri S.r.l.

a d v e r t i s e r s ’ gu i d e

Strada Gabrielassi, 15 1230 Caramagna Piemonte (CN) Italy 0172 89637

55 Global Cuting Systems

1237 Sanders Ave. Massillon OH 44647 330.883.2111

2 Hedstrom Plastics

1401 Jacobson Ave. Ashland OH 44805 USA 800.765.9665

9 Ingenia Polymers 200 Yorkland Blvd. Ste. 900 Toronto Ontario, M2J 5C1 416.920.8100 X6005 Richard.Levesque@

14 Norstar Aluminum

14101 Highway 290 W. Bldg. 1600B Austin, TX 78737 USA 512.894.4106

66 |

Rotoworld® • JANUARY-FEBRUARY 2012

Cedarburg WI 53012-0991 USA 262-375-5600

3 Orenda Automation

USA Headquarters 235 Progress Blvd. Kent, OH USA 44240 1.800.844.2927 / 330.677.2225 Europe Headquarters Ludwigsburger Str 13 Stuttgart, Germany 49.0711/8781-0 Rotoline Equipamentos

Industriais Ltda.

Brasil Corporate Office Acesso Canários da Terra, Lote 01, Quadra 2524. Bairro Seminário CEP: 89813-140 – CX Postal 160 Chapecó – BRASIL 55 49 3324 5680

67 Rotomachinery Group

Technologies Inc.

Via Crosa, 21/A

165 Steelcase Rd. East, Markham,

28065 Cerano (NO) Italy

Ontario, L3R1G1, Canada



20 VMP, Inc. 17 PSI Brand – a division of Polymer

24830 Ave. Tibbitts

Systems International Ltd

Valencia CA 91355-3404 USA

15 Thames St., Pandora,

888.4.VMP.INC 661.294.9934

Napier 4110

New Zealand

+64 6 833 6043

15 Powder King, LLC

64 JSJ Productions, Inc.

W66 N622 Madison Ave.

32-33 Reduction Engineering Scheer

41780 N. Vision Way

Unit 120 Bldg. 2 Anthem AZ 85086 USA




14101 Highway 290 West, Bldg. 1600-B Austin, TX 78737 USA




manufacturing & processing


Crossing Barriers with

5th Annual Nordic ARM Conference Highlights What’s Your Dream? 2012 StAR Conference Highlights 2011 ARM Hall of Fame Inductees: Jim Leitz and Daven Claerbout

RotoWorld Magazine  

Volume VIII, Issue 1, 2012

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