®
VOLUME XXII, ISSUE 2 • 2026
The Association that Helped Build a Global Industry
While the world automates, we elevate — with American craftsmanship that never cuts corners.
In an era where machines build machines and automation writes the rules, Pulverizing Manufacturing stands apart — by standing behind every nut & bolt, weld, and micron of precision. From raw material to final product, our pulverizing equipment is built start to finish on American soil, by American hands — engineered for performance, tested for durability, trusted worldwide.
Powder King® LLC • 41780 N Vision Way, Units 120-125, Bldg. 2 • Anthem, AZ 85086
623.551.9897 • www.powder-king.com
Made in the USA
CONTENTS FEATURES
On the Cover
42 42. Lower Temperatures, Higher Productivity: Flexahopper Saves Energy with NOVAPOL® TRx Resin Rotomolded products offer a variety of benefits, however the process can be energy intensive. Dave Sullivan, Technical Service Specialist at NOVA Chemicals
26
49
26. ARM at 50: The Association that Helped Build a Global Industry
49. ARM Executive Conference Belfast (June 9th – 11th)
It started with a conversation — It has grown into an industry legacy.
Lockdown in Belfast!
Susan Gibson, JSJ Productions, Inc.
Alvin Spence, Centro Incorporated
44 66 66. Spreadsheets Are Out. AI Is Running the Plant Better. AI is moving manufacturing from reactive to real-time, and driving higher plant output.
Jonathan Smalley, CEO, RotoEdge Pro
4 ROTOWORLD® ISSUE 2 • 2026
Innovation • Performance • Reliability
In-Stock Machines
Carousels 24 Models
In-Line Shuttles 13 Models
Rocking Ovens 5 Models
Work Platforms Fixed & Moving
Mixers
11 Models
Dispensing Systems
When Performance Counts... • Lowest Cost of Ownership • Highest Productivity, Durability • Remote Ethernet Machine Support • Automated Systems & Solutions
• Global Sales & Full Support • Over 1,400 Machines Globally • Energy-Smart Machines • Standard & Custom Machines
www.ferryindustries.com • sales@ferryindustries.com Ph: +1.330.920.9200 • Fx: +1.330.920.4200 • 4445 Allen Rd, Stow, OH 44224 USA © 2026 Ferry Industries, Inc.
www.rotoworldmag.com 5
UpFront — Diversified Mold & Castings 4th Generation of Leadership Continues to Grow
C O N T E N T S - D E PA R T M E N T S
20
Women In Roto — Flor Ponce, Director of Human Resources at Centro Incorporated
18
Roto Around the World — Temperature Control: Why IRT is Overtaking IAT in the Race for Automation
59 08. FROM THE PUBLISHER
The Magic of Fall—and the Promise of Renewal Susan Gibson, JSJ Productions, Inc.
10. CREDITS 12. GLOBAL CONTRIBUTING EDITORS Global Contributors, Department Contributors, and Issue Contributors
15. UPFRONT
Industry News, Trends, and Products
20. ROTO AROUND THE WORLD
70
ARMO News — Tim Leed Named 2026 Icon of Rotomoulding
59. WOMEN IN ROTO
Flor Ponce, Director of Human Resources at Centro Incorporated Conchita Miranda, Miraplastek – Mexico
38. AT ISSUE
Advancing Materials for the Future of Rotational Moulding Aldo Quaratino, Matrix Polymers
62. ARM REPORT
Our 50th Anniversary year is off to a great start!
70. ARMO NEWS
Tim Leed named 2026 ICON of Rotomoulding.
Temperature Control: Why IRT is overtaking IAT in the race for automation Ian Hansen, RotaConsult
76. GLOBAL CALENDAR
56. PRACTICAL ROTO TIPS
78. ADVERTISERS’ INDEX
Manufacturing: More Than Making Parts R. Dru Laws, Brigham Young University – Idaho
6 ROTOWORLD® ISSUE 2 • 2026
Industry Events
RotoWorld® advertiser contact information
25 Years of Unwavering Service Then, Now, and Beyond
We are thrilled to welcome back an original H1D500 Orenda Pulverizer for service after 25 years of outstanding performance. Here's to another 25 years of excellence and achievement.
www.rotoworldmag.com 7
FROM THE PUBLISHER
SUSAN GIBSON JSJ Productions, Inc.
The Magic of Fall—and the Promise of Renewal There is something magical about fall. The light changes, the air carries a hint of crispness, and nature reminds us how beautiful transformation can be. Even here in Texas, where cooler weather sometimes takes its time arriving, I feel that familiar anticipation. Fall brings the promise of fresh energy, new ideas, and a chance to look at the world a little differently. Perhaps it is the lingering back-to-school feeling that never quite leaves us—the thought of a clean notebook, an interesting conversation, or something new to learn. After the busy pace of summer, autumn invites us to gather our thoughts and return to our work with renewed purpose. Of course, ours is a global community, and many of our readers are welcoming spring rather than fall. Yet both seasons carry a sense of possibility. Whether the leaves are turning or new blossoms are appearing, the message is much the same: there is always room to grow. That spirit of renewal makes this an especially meaningful year for our industry. In 2026, the Association of Rotational Molders celebrates its 50th anniversary. Since its founding on February 5, 1976, ARM has helped bring people together to exchange knowledge, support research, and advance the rotational molding process. Fifty years represents a remarkable investment in an industry and its people. When we celebrate an anniversary like this, it is natural to think about how much has changed. Materials, machinery, product design, and manufacturing practices have evolved. New applications have expanded our understanding of what rotational molding can accomplish. Each generation has brought its own challenges, discoveries, and ambitions. The heart of the story is the people. It is the entrepreneur who saw an opportunity and had the courage to build a business. The technician who kept asking questions until a difficult problem was solved. The supplier who became a trusted partner. The experienced molder who took time to help a newcomer understand the process. And the volunteers who gave their time because they believed
8 ROTOWORLD® ISSUE 2 • 2026
a stronger association could help build a stronger industry. Their contributions remind us of that progress often begins with a conversation. Someone shares an experience, offers a suggestion, or asks, “Have you tried this?” Across companies, countries, and generations, those exchanges create possibilities that none of us could discover alone. As a publisher and editor, that is one of the things I value most about this industry. Behind every product, technical development, and company milestone is a human story. Sharing those stories helps us understand our work more fully—and appreciate the imagination and persistence it requires. Fall offers a timely invitation to bring that curiosity into our own businesses. We can revisit an idea that was set aside, encourage a younger colleague to contribute, reconnect with an industry friend, or make time to learn something outside our usual routine. Renewal does not always require a dramatic change. Sometimes it begins with one thoughtful step. We congratulate ARM and everyone who has helped shape its first 50 years. As we honor that history, let us also carry its spirit of cooperation forward. Here’s to the magic of the changing seasons, the pleasure of discovery, and the friendships that enrich our work. May we enter the months ahead with gratitude for what has been accomplished—and enthusiasm for what we can create together.
SUSAN DIANNA GIBSON Publisher & Editor
Positively Jerico! Your Distributor of Choice for PE and PP
Jerico is your distribution partner for: • BayStar PE • Rotoworx PolyPro PP
And your one-stop shop for: • Custom Compounding • Cross-link • Post-Consumer Recycled • Post-Industrial Recycled • Adhesion Compounds • Stone Effect Special Effect • Econo-grade Natural and Color
Contact Jerico for solutions to your rotomolding and compounding challenges!
(330) 868-4600
info@jericoplastic.com Member of ROTOMARKETPLACE Innovative. Buying. Power.
Congratulations to The Association of Rotational Molders on 50 Years! Committed to Excellence in Rotational Molding Family-Owned and Operated Since 1997
JERICOPLASTIC.COM
(330) 868-4600 info@jericoplastic.com www.rotoworldmag.com 9
PUBLISHER & EDITOR Susan D. Gibson President - JSJ Productions, Inc. susan@jsjproductionsinc.com TECHNICAL EDITOR Alvin Spence PhD MEng aspence@centroinc.com PROCESS EDITOR Paul Nugent PhD MEng paul@paulnugent.com DESIGN EDITOR Michael Paloian President - Integrated Design Systems, Inc. paloian@idsys.com GLOBAL CONTRIBUTING EDITORS Celal Beysel Chairman - Floteks Plastik beysel@superonline.com Tom Innis Xcelerant Growth Partners info@xcelerantgrowthpartners.com Martin Coles Matrix Polymers martin.coles@matrixpolymers.com Adam Covington Ferry Industries acovington@ferryindustries.com Mark Kearns Moulding Research Manager m.kearns@qub.ac.uk Ravi Mehra Managing Director - Norstar International LLC maramehra@aol.com ADVERTISING AND ART PRODUCTION Marketing/Advertising Director Jennifer Gibson Hebert Vice President, JSJ Productions, Inc. jennifer@jsjproductionsinc.com
Chief Art Director Anya Wilcox JSJ Productions, Inc. awilcox@designintersection.com CIRCULATION & DISTRIBUTION ADMINISTRATION Sheryl Bjorn JSJ Productions, Inc. sheryl@jsjproductionsinc.com EDITING & TRANSLATIONS Suzanne Ketron | Oliver Wandres | Sheryl Bjorn WEBSITE & ONLINE TECHNOLOGY Jason Cooper JSJ Productions, Inc. jason@bound.by RotoWorld® is a JSJ Productions, Inc. Trade Publication 625 West Market Street, Salinas, CA 93901 Phone: (512) 894.4106 Email: rotoworldmag@rotoworldmag.com and Website: www.rotoworldmag.com Subscriptions: One-year subscription (four issues), print or digital, $80 US, $100 Canada/Mexico, $155 All Other Countries. To subscribe or to submit change of address information, call us at (512) 894.4106 visit us online at www.rotoworldmag.com; or email us at sheryl@jsjproductionsinc.com. You may also write to RotoWorld® Subscriptions, 625 West Market Street, Salinas, CA 93901 Advertising: For information on advertising, please contact Advertising Director Jennifer Gibson Hebert, RotoWorld® Email Jennifer Gibson at jennifer@jsjproductionsinc.com Letters: We welcome letters about our contents. Write Letters to the Editor, RotoWorld®, 625 West Market Street, Salinas, CA 93901 512.894.4106 phone 512.858.0486 fax, or Email susan@jsjproductionsinc.com. Editorial Queries: We consider unsolicited contributions. Send manuscript submissions as email attachment to Susan Gibson at susan@jsjproductionsinc.com. JSJ Productions, Inc. bears no responsibility for claims or factual data represented in contributed articles. JSJ Productions, Inc. acknowledges AI is sourced and utilized in RotoWorld® editorial. Postmaster: Send changes of address to RotoWorld®, 625 West Market Street, Salinas, CA 93901. RotoWorld® is a private, independently owned, quarterly trade magazine for the international rotational molding and plastics design industries. RotoWorld® owns all copyrights on articles published herein unless ownership is otherwise stated. Reproduction of this magazine, in whole or in part, without the express written permission of the publisher is not permitted.
10 ROTOWORLD® ISSUE 2 • 2026
Our Polyamide 6 powder Without N2 Competitor Without N2
Competitor With N2
When standard polymers won’t cut it
Polyamide 6 Roto powders for technically demanding
WHY PA
Y FOR N Matrix ITROGE N? exceptio Polymers Poly amide 6 n N₂ purge al mouldability delivers without , helping the need reduce for an cost, sim and imp plify pro rove pro cessing ductivity
applications
SIMPLER PROCESS
LOWER COSTS Eliminate the cost of nitrogen gas, equipment and associated set-up
No purge means easier set-up, less complexity and fewer interruptions
Our advanced
Polyamide 6 Roto
powders deliver outstanding mouldability without the need for a nitrogen purge, reducing process complexity, operating costs and cycle interruptions
Faster start-ups, consistent cycles and improved throughput
UNDERTHE-HOOD READY
NO N₂ PURGE REQUIRED
Fluid Level Visible The natural translucency of Polyamide 6 allows customers to visually monitor fluid levels without additional sensors or sight glasses
MORE PRODUCTIVE
Our Polyamide 6 Roto powders are under-the-hood ready, engineered to support durable components for demanding automotive applications
PAINTABLE Our Polyamide 6 is easily paintable, delivering excellent adhesion and highquality finish for a wide range of applications
PREPARED FOR THE CHALLENGE Contact Margaret or Jake to discuss your options margaret.molloy@matrixpolymers.com jake.kelly-walley@matrixpolymers.com matrixpolymers.com
www.rotoworldmag.com 11
CONTRIBUTING EDITORS
PAUL NUGENT
design editor
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 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. paul@paulnugent.com contributing editor
12 ROTOWORLD® ISSUE 2 • 2026
MARTIN COLES
Martin Coles, CEO of Matrix Polymers co-founded the business 30 years ago and is the company’s largest shareholder. Shortly after graduating from London University, Martin began his career in the plastics industry working for a major Italian petrochemical company and soon became passionate about the unique world of rotomoulding. Matrix Polymers are experts in rotomoulding materials and have become a global supplier with compounding and grinding plants in the UK, Poland, Australia, Thailand, New Zealand and Malaysia. The company sells more than $150 million of rotomoulding materials each year and has 230 employees. martin.coles@matrixpolymers.com contributing editor
MICHAEL PALOIAN
Michael is President of Integrated Design Systems, Inc., Great Neck, New York. 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 basis for his branded and unique insights into the field of plastics part design. paloian@idsys.com
contributing editor
process editor
technical editor
ALVIN SPENCE
Alvin Spence is Vice President Engineering at Centro, Inc., North Liberty, Iowa. He provides leadership for Centro’s product development team and quality resources. Alvin received his Bachelor’s degree in Mechanical & Industrial Engineering and PhD from Queen’s University Belfast. aspence@centroinc.com
RAVI MEHRA
Ravi Mehra has been associated with the rotational molding industry since the early 1970’s. He is a Past President of ARM – Association of Rotational Molders, and has been inducted into the ARM Hall of Fame. He is the Founding Chairman of StAR – the rotational moulding Trade Association of India. He was the Chairman of ARMO – Affiliation of Rotational Moulding Organizations from 2012 to 2014. Ravi consults internationally with companies in the rotational moulding arena to help their global strategy, facilitate technology tie-ups, and business alliances. maramehra@aol.com
CELAL BEYSEL
Celal is Chairman of Floteks Plastik, the pioneer and innovative leader of the rotational molding industry in Turkey and is a Global Contributing Editor for RotoWorld® magazine. Being an ARM member for more than 20 years, Celal has made many presentations at ARM meetings in various countries. He is also active in business and political organizations in his country. Celal has authored numerous articles published in various newspapers and magazines about politics, plastics, rotomolding, and innovation. beysel@superonline.com
CONTRIBUTING EDITORS
ADAM COVINGTON
department editor
department editor
ROB MILLER
Rob Miller is Owner/President, Wittmann Battenfeld Canada Inc./ Rotoload. Rob started in the plastics pneumatic conveying industry in 1986. He has spent his entire career developing, engineering, and designing all types of catalog, standard, and custom pneumatic conveying systems for the plastics industry. He started in the rotational molding industry in 2013, has enjoyed learning the idiosyncrasies of the industry and market, and most of all meeting the people and building relationships for the future. Rob.Miller@wittmann-group.ca
IAN HANSEN
Ian Hansen has over 30 years of experience in the rotational moulding industry and has presented to conferences around the world on the subject of quality, safety, and tank design standards. Rotomoulders around the globe have problems from time to time. Rota Consult delivers production solutions so rotomoulders can improve productivity and profitability, without wasting more of their valuable time. ianhansenconsult@gmail.com
MARK KEARNS
Mark Kearns 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. M.Kearns@qub.ac.uk department editor
Adam Covington is President of Ferry Industries, Inc. in Akron, Ohio U.S.A. Covington has been with Ferry Industries for over 11 years, advanced through the manufacturing, engineering, sales, and service positions within the company and was appointed President in 2019. Adam strives to find solutions for customers’ needs and advance machine technology for the rotomolding industry. He is a graduate of Ohio University’s Russ College of Engineering and Technology with a Bachelor’s degree in Industrial Technology. acovington@ferryindustries.com
contributing editor
contributing editor
contributing editor
ALDO QUARATINO
As Group Technical Director of Matrix Polymers, Aldo Quaratino spearheads the company’s research and development initiatives. He leads a dedicated team in identifying new opportunities and crafting innovative solutions to address the dynamic needs of their customers. Aldo’s deep expertise in polymer science has been the driving force behind many of Matrix Polymers’ groundbreaking advancements. Under his leadership, the company has developed a suite of high performance polymers that have revolutionized the rotomoulding industry.
R. DRU LAWS
R. Dru Laws, educator and rotomolding expert, graduated from Brigham Young University in 2003 with a BS in Mechanical Engineering and a minor in Mathematics. In 2005, he graduated top of his class with distinction (honors) from the Queens University Belfast in Northern Ireland with an MSc in Polymer Engineering from their school of Mechanical & Manufacturing Engineering. He has several rotomouldingrelated patents. Laws is currently a full-time Manufacturing Engineering professor at BYUIdaho, as well as CEO of Halltech Systems and High Pointe Plastics. drulaws@gmail.com
www.rotoworldmag.com 13
ISSUE EDITORS
JONATHAN SMALLEY
Since 2007, Mr. Smalley has led SmaK Plastics to become one of the most trusted, full-service rotational molding companies in the USA. SmaK Plastics is the parent company of well-known industry brands: RotoEdge Pro™ advanced rotational molding production management and scheduling software; Flextank advanced oxygen-permeable polyethylene tanks and hoppers; U.S. Products highquality floor cleaning and spot extractors, wands, tools, and powerful restoration flood extractors; and Columbia MFG, producer of dielectric strength pole line hardware and double-locking secondary pedestals for utilities and contractors. In 2017, Mr. Smalley architected the development of RotoEdge ProTM software. Mr. Smalley’s vision was to empower the rotational molding industry through innovative software solutions that drive efficiency, sustainability, and growth. RotoEdge ProTM software was created to solve complex challenges that Rotomolders face: from scheduling, to inventory control, machine and arm productivity management, order tracking, worker training, and scrap reduction.
14 ROTOWORLD® ISSUE 2 • 2026
Today, Mr. Smalley is leading the effort to add AI to RotoEdge ProTM. This addition of AI technology will simplify the use of real-time data provided to Rotomolders, and will further help them increase productivity and customer delivery in today’s fast-paced market. Mr. Smalley lives with his family in Vancouver, Washington, and in his spare time enjoys heading Smalley Racing, an established local race team with three generations of drivers.
DAVE SULLIVAN
Dave Sullivan is a Technical Services Specialist at NOVA Chemicals with more than a decade of experience in research and technical roles within the petrochemical industry. His industry expertise spans several areas of polyethylene applications, with a primary focus on rotational and blow molding.
UPFRONT
LYB earns Toyota Motor Europe award for circular polymers from maritime waste
ROTTERDAM, NETHERLANDS — LyondellBasell (NYSE: LYB) earned a sustainability award from Toyota Motor Europe for advancing circular material solutions for automotive applications. Toyota Motor Europe presented the award at its Annual Business Meeting May 7, 2026 in Belgium. The company recognized LYB innovation and longterm collaboration to develop postconsumer recycled (PCR) polymer solutions made from end-of-life fishing nets. Toyota plans to incorporate the materials into future vehicles, supporting sustainability goals, while maintaining high performance and quality standards. “This recognition is an honor for our teams,” said Frank Noeltgen, vice president of Advanced Polymer Solutions Europe at LYB. “Toyota sets a high bar for innovation and engineering excellence, and we’re proud to support an OEM of this caliber. Developing circular solutions takes persistence, technical rigor, and trusted
collaboration, and we value our partnership with Toyota as we continue to drive progress together.” Over the past two years, LYB teams worked closely with Toyota to plan, evaluate and validate PCR-based materials derived from end-of-life fishing nets recovered from maritime environments. The teams conducted extensive testing and performance evaluations to ensure the materials meet the rigorous requirements of automotive applications. This collaboration demonstrates the LYB ability to translate complex waste streams into highvalue materials that support circularity at scale. By combining materials science expertise with customer focused development, LYB enables more sustainable vehicle design without compromising safety, durability or quality. Looking ahead, LYB will support the development of Toyota’s end-of-life vehicles through the LYB closed-loop preparation center. R
www.rotoworldmag.com 15
UPFRONT
MAAG Group to Acquire Cloeren Incorporated OBERGLATT, SWITZERLAND — The MAAG Group recently announced that it has signed a definitive agreement to acquire Cloeren Incorporated (“Cloeren”), based in Orange, (Texas), USA. With this strategic acquisition, the Group is expanding its expertise in plastics processing and strengthening its position as a leading global provider of integrated system solutions for the polymer and plastics industry. Cloeren designs and manufactures highperformance, customdesigned extrusion slot dies and feedblocks primarily for polymer and plastics applications. The Company is based in Orange, TX, in close proximity to North America’s petrochemical and energy export hub, with additional manufacturing locations in Marshall, Texas/USA; Eau Claire, Wisconsin/USA; and Micheldorf, Austria. Cloeren is a global leader in the production of extrusion dies, with highly regarded technical capabilities and a blue-chip customer base. The acquisition adds complementary extrusion technologies to MAAG’s portfolio and expands its ability to serve customers with a broader, more complete solution across polymer processing applications. With Cloeren, MAAG Group is gaining a technologically leading partner whose products, expertise, and track record of innovation perfectly complement our existing portfolio. By combining the expertise of both companies, the MAAG Group is laying the foundation for further sustainable growth and strengthening its development capabilities across the entire plastics processing value chain. Going forward, customers will benefit from an even broader portfolio of solutions, greater process expertise, and an expanded range of technologies for demanding applications.
16 ROTOWORLD® ISSUE 2 • 2026
“Cloeren is a strong strategic fit for MAAG and will further enhance our capabilities in extrusion applications,” said Ueli Thuerig, President of MAAG. “The addition of Cloeren’s technologies and engineering expertise expands our solutions offering and strengthens our ability to support customers with highly engineered, mission-critical equipment.” “We are very much looking forward to becoming part of the MAAG Group. Both companies share a commitment to combining technological excellence with a consistent focus on the customer. By combining our strengths, we will create additional value for our customers, tap into new market potential, and accelerate the development of innovative solutions,” said Peter Cloeren, President of Cloeren Incorporated. Cloeren’s existing business operations will continue as usual. Customers and business partners will continue to benefit from the company’s proven products, services, and dedicated staff, as well as from the expanded resources and opportunities available within the MAAG Group. The transaction is expected to close in the third quarter following satisfactory completion of customary closing conditions. The terms of the transaction were not disclosed. For more information about the MAAG Group’s products and solutions, please visit www.maag.com. R
Global Supplier of Speciality Rotomoulding Materials
CROSSLINK PE
FLAME RETARDANT COMPOUNDS
HYPERENE HDPE GRADES
DIESEL TANK SERIES | GENERAL PURPOSE SERIES | TANK SERIES | ROTOLINING SERIES
M A L AYS I A
|
INDIA
|
PHILIPPINES
|
USA
enq@polymerlink.in | www.polymerlink.in
|
AUSTRALIA
www.rotoworldmag.com 17
UPFRONT
Diversified Mold & Castings 4th Generation of Leadership Continues to Grow. WARRENSVILLE HEIGHTS, OH USA — Diversified Mold & Castings (DMC), a leader in rotational mold building, is proud to announce the continuation of its family legacy as the company welcomes another family member into the fourth generation of leadership. Nicholas Steven Costello joined DMC full-time in 2026, following his graduation from Miami University. Nicholas earned a Bachelor of Science in Marketing. His academic background and firsthand experience with DMC provide a solid foundation as he takes on new responsibilities and contributes to the organization’s continued growth and success. “Cindy and I are very happy to welcome our middle son, Nicholas, to the company full time,” said Vince Costello, CEO of Diversified Mold & Castings. “Since starting full time in July, Nicholas has demonstrated dedication, a strong work ethic, and a willingness to help in any department as he expands his knowledge of our industry. He will no doubt be an important part of DMC’s future.” Currently serving as Marketing Specialist, Nicholas focuses on DMC’s marketing efforts, creating content and managing its presence across multiple social media platforms while supporting sales initiatives and continued growth throughout the company. He continues to gain firsthand experience across the organization and support other departments as needed. Having worked at DMC during summers and school breaks for more than ten years, Nicholas has developed a strong understanding of the company’s operations as he transitions into a full-time role. “I’m proud to have the opportunity to continue growing with DMC and contribute to the future of a company that has been such an important part of my family for generations,” said Nicholas Costello. “Having grown up around the business, I have experienced
18 ROTOWORLD® ISSUE 2 • 2026
firsthand the importance of attention to detail and quality at DMC. I am excited to build on that foundation, continue expanding my knowledge of the industry, and contribute to the company’s future.” As Diversified Mold & Castings enters its 88th year in business, the company is proud to have continued growth into the fourth generation and looks forward to continuing its tradition of quality, innovation, and customer service for years to come. DMC extends sincere thanks to its loyal customers for their continued support, which has enabled the company to grow its expertise and expand its offerings within the rotational mold industry. For more information, contact Diversified Molds & Castings by calling 216.663.1814 or toll-free 1.888.642.1222, or visit www.diversifiedmolds.com. R
UPFRONT
Myers Industries Completes Sale of Myers Tire Supply AKRON, OH USA — Myers Industries, Inc. (NYSE: MYE), a leading manufacturer of Products that Protect™, today announced it has entered into and completed an agreement to sell its Myers Tire Supply (MTS) North America business to Lion Equity Partners, a Denver-based private equity firm specializing in corporate divestitures. Under the terms of the agreement, Myers will receive $30 million, subject to certain customary postclosing adjustments for cash, indebtedness, net working capital, and transaction expenses. The definitive transaction agreement will be filed with the Securities and Exchange Commission as an exhibit to the Company’s Current Report on Form 8-K. The sale advances Myers’ Focused Transformation into a manufacturer of engineered resin and composite products serving critical infrastructure, industrial, consumer, food and beverage, and vehicle end markets. The transaction strengthens Myers’ balance sheet and enables the Company to
concentrate resources on its core businesses and growth platforms. Myers Industries President and CEO Aaron Schapper commented, “The completion of this transaction is a defining step in our ongoing transformation. By sharpening our focus on our core specialty engineered products, we are better positioned to drive long-term growth and create value for our shareholders. “We also want to recognize the important role Myers Tire Supply has played throughout our history,” he added. “We are grateful for the dedication of the MTS team and the trusted relationships they have built with customers and the rest of the Myers team over many decades. We believe the business is well positioned for its next phase of growth under Lion Equity Partners’ ownership.” For more information, visit myersindustries.com R
Masquerade
Paper Faces on Parade Join Us After the Gala as we Celebrate 50 Years of ARM! Open Bar + Music + Late Night Bites Thursday, November 19, 2026
10th Anniversary as Exclusive After Party Sponsor | See Us at Booth #413! Committed to Excellence in Rotational Molding. Family-Owned and Operated Since 1997.
(330) 868-4600 info@jericoplastic.com
JERICOPLASTIC.COM www.rotoworldmag.com 19
ROTO AROUND THE WORLD
IAN HANSEN RotaConsult
Temperature Control: Why IRT is Overtaking IAT in the Race for Automation For decades, rotational moulders have accepted a fundamental truth: the process is driven by temperature, not by time. Yet, a vast majority of operations still rely on the legacy habit of “guessing by the clock.” At the ARMA Rotomould 2026 conference in Melbourne, Australia, an engaging presentation titled “Advantages of InfraRed Thermometry (IRT) for Process Control” challenged this status quo before a global audience of moulders and suppliers. The industry is reaching a tipping point. The continued evolution of InfraRed Thermometry (IRT) is overcoming the operational headaches of traditional Internal Air Temperature (IAT) systems, paving the way for a fully automated, hands-free, and closedloop future in temperature-controlled manufacturing.
20 ROTOWORLD® ISSUE 2 • 2026
ROTO AROUND THE WORLD
A Tale of Two Technologies: The Historical Path
The quest for thermal discipline in rotomoulding follows two distinct lineages. Internal Air Temperature (IAT) measurement has long been considered the “gold standard” for process analysis because it measures the actual air profile inside the mould to pinpoint optimum polymer cure and cooling points. Queen’s University Belfast (QUB) pioneered this field by developing Rotolog™ in the late 1980s, a technology Ferry Industries Inc. (Ferry) ultimately acquired in 2002. Since those foundational patents expired, the market has seen a variety of competitive IAT systems commercialized, including Templogger, K-Paq, and EZLogger. While IAT revolutionized our fundamental understanding of the process, it presented severe operational hurdles on high-volume factory floors. Running a physical thermocouple probe through the vent tube of every single mould, on every single cycle, is labourintensive, highly prone to operator error, and brutally demanding on heat-sensitive electronics cycling through an oven. To solve this, researchers at QUB in the late 1990s developed a non-contact alternative that monitored the outside surface of the mould instead. Ferry successfully commercialized this in the early 2000’s as a factoryhardened system known as the InfraRed Thermometry (IRT)™. Crucially, instead of acting purely as a diagnostic data logger like early iterations of IAT, IRT was wired directly into the machine’s
primary Programmable Logic Controller (PLC). This achieved true closed-loop machine control. The PLC could now automatically terminate the oven heating phase or stop the cooling cycle the exact moment the outer mould surface hit its targeted thermal threshold—effectively eliminating fixed-time control. While the original Ferry IRT system
automation-driven control. The core distinction of IRT is that it is not intended to dictate what a cycle should be; rather, its purpose is to guarantee the absolute repeatability of heating and cooling temperatures from one cycle to the next. By monitoring mould surface temperatures in real time, IRT eliminates the need for physical
was protected by patents, these have since expired, opening up the technology for widespread industry adoption.
attachments, thermocouple cables, or internal probes.
From Diagnostics to Automation
Although both IAT and IRT technologies were originally engineered for machines operating biaxial rotation arms in hot air ovens, IAT has also served as the primary, cost-effective temperature
While IAT systems evolved as an in-mould diagnostic tool designed to help engineers map polymer phase changes, IRT represents a paradigm shift toward non-contact,
Bridging the Gap in Rock and Roll Manufacturing
www.rotoworldmag.com 21
ROTO AROUND THE WORLD
solution for open-flame Rock and Roll (R&R) machines. As a moulder 25 years ago, we measured Peak Internal Air Temperature (PIAT) on largevolume R&R tanks (5,000 to 45,000L or 1,300 to 12,000USG) using only a relatively cheap stainless-steel thermocouple, a trailing cable, and a portable handheld meter to monitor manually every single cycle. Today, the technology has matured significantly. Advanced moulders now utilize wireless thermocouple transmitters that automatically log and display IAT data via a wireless receiver, seamlessly recording and controlling the PIAT, hands free, for every large tank that leaves the line.
Why IAT Stalls in Production
Despite its precision, IAT often fails as a continuous, day-to-day production tool because of the repetitive manual intervention it demands from operators. Managing IAT hardware on a highvolume factory floor introduces two major operational bottlenecks:
Coolant Pack Discipline: Operators must strictly swap internal phase-change gel packs every two to three cycles. Forgetting this single step can instantly destroy expensive transmitter electronics inside the oven.
Overcoming the Industry Status Quo
Despite the availability of affordable, advanced process control technology, a stubborn resistance to adopting continuous temperature control persists across the industry—regardless of whether a facility utilizes R&R open flame or biaxial hot air ovens. A common legacy mindset suggests that if a machine is currently producing “acceptable” parts using traditional methods, there is no justification for capital investment. However, relying strictly on operator intuition and static cycle times introduces unnecessary risk into a modern operation. In an increasingly competitive global market, transitioning from human guesswork to automated data control is no longer just an optional upgrade; it is the key to true manufacturing consistency.
The Hardware Headache:
22 ROTOWORLD® ISSUE 2 • 2026
“TRANSITIONING FROM HUMAN GUESSWORK TO AUTOMATED DATA CONTROL IS THE KEY TO TRUE MANUFACTURING CONSISTENCY.”
The Thermocouple Maintenance Burden: Type-K thermocouples must be routed through vent pipes where the wires regularly kink, break, or become coated in molten polymer. This requires constant maintenance and forces operations to treat probes as expensive consumable items.
From Observation to Automation: The Data
The true power of IRT is revealed when mould temperature monitoring moves from “observation mode” to active, closed-loop control. In observation mode, plotting fixed oven
ROTO AROUND THE WORLD
variations in operator efficiency, and “first cycle of the day” coldstart effects. When the IRT system takes the wheel, it can adjust the machine in real time. Instead of a timer, the heating and/or cooling stop time is dictated purely by the mould reaching a target exit temperature.
56 cooling cycles for the same straight arm, with the same mould combination, maintained an average cooling station mould exit (stop) temperature of 44°C (with a relatively small 1.7 deviation) by automatically varying the actual cooling time by as much as 6 mins. The 34-Cycle Consistency Run: A different straight arm, maintaining the same mould settings, was able to stop the cooling cycle at an average 89°C, (±3°C) The IRT system dynamically varied cooling times by ±6mins to compensate for environmental & process variables. Why did these case studies focus on cooling, instead of heating? One reason is because the biggest opportunity to save production time in rotational moulding generally lies in cooling time reduction. Another is the cooling sequence has a significant effect on shrinkage and warpage and final product performance.
Case Studies in IRT Automation
Consistency vs Perfection
56 Cycles
cycle times against mould exit temperatures reveals significant, costly process drift. While the fixed times may be “good enough” for most heating & cooling cycles, IRT control is better temperature control for all cycles. Data collected from an Australian, 3-arm carousel, reported on 34 heating cycles of the same offset arm, showed that even with identical machine settings, mould exit temperatures from the oven fluctuated by ±5% due to ambient factory shifts,
The 56 Cycle Study: An Australian carousel IRT system reported on
IAT vs IRT is like comparing internal resolution vs. efficient automation. IRT is the “Production Standard” with continuous monitoring of the exterior mould surface. In the majority of rotomoulding production environments consistency is more important than perfection. IRT will win the consistency race.
IRT in the Field: Success Stories Moulders are already leveraging these automated advantages across diverse, real-world applications: 1. Single spot lasers. Singlespot infrared temperature 34 Cycles www.rotoworldmag.com 23
ROTO AROUND THE WORLD
IAT and IRT temperature data. This hybrid approach allows them to produce high-value Type IV hydrogen storage tank liners with the exact thermal precision typically reserved for electrically heated moulds. 3. Full-Profile Thermal Imaging. Rotomachinery Group and Rotoplastic Srl have recently started to offer the more complex, more expensive infrared thermal camera system, as an optional enhancement for their machines, to optimise heating and cooling cycles. When thermal cameras are integrated with machine control, they also enable automation capability.
The Next Frontier: Controlling the Rate of Cooling “THE NEXT FRONTIER IN PROCESS CONTROL IS NOT JUST STOPPING THE CYCLE AT TEMPERATURE — IT IS CONTROLLING THE RATE OF COOLING WITH PRECISION.”
sensors (pyrometers) are highly capable of measuring the average external surface of moulds on straight or offset arms, especially where the mould surface area is large relative to the external framing or oven walls. Ferry Industries pioneered this space by offering IRT as an integrated option on their Rotospeed machines. IRT can operate on any mould, but large-volume parts, such as water tanks, typically feature large surface areas that are ideally suited to advanced, but less complex, lower-
24 ROTOWORLD® ISSUE 2 • 2026
cost single-spot IRT sensors compared to more expensive, more demanding thermal imaging cameras. The Ferry Industries proprietary InfraRed Thermometry (IRT)™ system, (and Rotolog™) is available as an optional enhancement to RotoSpeed machines with RotoCure 7.0. 2. Rock & Roll Hydrogen Tank Innovation. At the StAR conference, Floteks (Türkiye) introduced an innovative openflame Rock & Roll machine utilizing unified closed-loop
The next evolutionary step in process control—championed for over 15 years by Dr. Gareth McDowell of 493K—moves beyond simply stopping a cycle at a predetermined temperature. The new frontier focuses on actively controlling the rate of cooling. Future machine control architectures will use IRT to measure mould temperature in real time, compare it against a predetermined “cooling plan,” and automatically adjust fan speeds and water mist flow rates. This will ensure a perfectly consistent cooling gradient regardless of changes in ambient. R
DIVERSIFIED MOLD & CASTINGS
CNC Molds
OVER
Fabricated Molds
Cast Aluminum Molds
YEARS STRONG
www.rotoworldmag.com 25
The Association that Helped Build a Global Industry Susan Gibson, JSJ Productions Inc.
26 ROTOWORLD® ISSUE 2 • 2026
ARM Board Meeting with Ravi Mehra at the Helm
It star ted with a conversation.
F
or half a century, the Association of Rotational Molders has brought competitors, suppliers, researchers, and innovators together around a common purpose: advancing rotational molding. What began with a small gathering in Chicago in 1976, grew into an organization whose education, research, technical resources, meetings, and culture of cooperation helped shape a global industry. Fifty years ago, a group of rotational molders gathered at the O’Hare Hilton in Chicago around a manufacturing process that was still finding its place in the plastics industry. They were competitors. Many
were entrepreneurs accustomed to solving their own problems, protecting their own markets, and finding their own way. Yet, something unusual happened in that room. They began talking to one another. Patrick K. Long, who was 25 when he attended the February 5, 1976 organizational meeting with his father, Thomas J. Long, later remembered wondering how his father would react to being in a room filled with competitors. He found the gathering remarkably collegial. The willingness to share—the characteristic that would become one of ARM’s defining traits—was evident from the beginning. Sixteen companies agreed
Early ARM members www.rotoworldmag.com 27
The Early Years!
L-R: Early ARM Trade Show; Gareth McDowell; Robert Grossman; Erich Boersch; Eleanor and Thomas J Long; Corkey Carlsen; Chuck Carlsen; Tom Schidel; Jose and Concepción Miranda; and Peter Connors, Phil Dodge, Barry Aubrey, and David Mulligan
28 ROTOWORLD® ISSUE 2 • 2026
L-R: Peggy and Bill Burlingham; Glenn Beall; Ravi and Manju Mehra; Concepción Miranda and Ravi Mehra; Bill Blaiklock; Carl, Daven, Bill, and Nancy Claerbout; Jack Schneider and Sherman McKinniss; and ARM Hall of Fame
www.rotoworldmag.com 29
to contribute $250 each in seed money to get the proposed association underway. By the second meeting on April 20, 1977, 49 representatives from 45 companies were present. The committees they created revealed how clearly those founders understood what their young industry needed: Program Topics, Education, Technical, Standards/Specifications, Materials, etc. The organization they created became the Association of Rotational Molders. Two-time ARM Past President Ravi Mehra, Nalge Nunc International, who began attending ARM meetings in 1977, said: “It was apparent to me from the beginning that the companies there were small and represented by a bunch of young and eager entrepreneurs. The best thing that came out of that first meeting I attended was that this organization would provide a platform for the molders to learn the challenges of the industry and find solutions together. It was the only such association in the world for rotomolding.” Five decades later, it is difficult to separate ARM’s history from the evolution of modern rotational molding. The process has changed enormously between 1976 and 2026. Materials have improved. Machines have become more sophisticated. Process controls have transformed production. A multitude of new markets have emerged. Automation and robotics have entered plants. Digital technologies have changed the factory floor. Rotomolded products have moved far beyond the applications that were once associated with the process. Through those changes, ARM has served as a catalyst—bringing people together, organizing technical knowledge, creating educational resources, supporting research, connecting molders with suppliers and researchers, recognizing innovation, developing leaders, and providing a forum where the people who knew rotational molding best could learn from one another. The remarkable part is that ARM accomplished much of this by encouraging people who competed in the marketplace to cooperate in advancing the process.
Building the Foundation
Some of ARM’s most consequential decisions came surprisingly early. The fledgling organization was invited to become part of the Society of the Plastics Industry (SPI), but its leaders chose instead to remain
30 ROTOWORLD® ISSUE 2 • 2026
independent while cooperating with the larger plastics organization. The decision gave rotational molding an identity and visibility of its own. ARM also wrestled with the role of suppliers. Initially, suppliers could become members but not voting members; over time, their participation expanded, and they became integral to the Association’s technical and financial strength. ARM also looked beyond the United States almost immediately. International membership was established in 1977 as companies outside the country sought to participate. International members began contributing to meetings and workshops and eventually served in Association leadership. But perhaps ARM’s most important early contribution was turning individual experience into shared industry knowledge. In those years, much of what people knew about rotational molding resided inside individual companies and in the heads of experienced molders. Information existed, but it was fragmented. Well-known industrial engineer Glenn Beall helped change that. Working through ARM, Beall gathered the collective experience of the industry and developed a practical design manual. He later recalled that injection molding had long possessed design manuals, while rotomolding lacked a comparable resource. ARM members pooled their ideas and experience to establish design practices that could be communicated not only to molders but to the product-design community. Pat Long would later identify the design manual as one of ARM’s greatest early accomplishments, crediting it with helping establish rotational molding as a legitimate alternative for designers evaluating manufacturing processes. This pattern would repeat throughout ARM’s history: identify a barrier to the process, bring together people who understand it, organize their knowledge, and make that knowledge useful to others. ARM also began promoting excellence. By the early 1980s, its product Achievement Awards were evolving into categories recognizing Conversion Applications, Innovation, State-of-the-Art Products and Large Products, with an overall Product of the Year selected from the entries. The awards did more than recognize companies for their innovative works. They helped demonstrate what rotational molding could do. As applications expanded, so did ARM’s ambitions. ARM member since 1989, Dr. Paul Nugent attended his first meeting in London along with Professor Roy Crawford. Paul said: “ARM’s formation in 1976 created a focal point for the industry which has allowed
molders, suppliers, and academics to take a process long shaped by entrepreneurial drive and hands-on experience to one that is now underpinned by deep technical understanding of the materials, processes, and long-term performance of high-tech products once only imagined by those early pioneers.”
Turning Experience into Science
If the design manual helped organize what the industry already knew, the next challenge was generating knowledge it did not yet have. By the mid-1980s, ARM leaders were discussing something far more ambitious: an institution devoted to rotational molding research, education, and testing. The result was the Rotomolding Development Center. Under President Ravi Mehra, ARM provided financial backing for the center’s establishment in Akron, Ohio. The concept was significant: rotational molding needed basic research that could deepen understanding of materials, processing, and product performance. ARM was prepared to help create the infrastructure for that work. By the end of the decade, that research effort had become centered at Queen’s University Belfast under Professor Roy Crawford. Crawford, now deceased, became one of the paramount figures in the technical evolution of rotational molding and in ARM’s history. His importance extended far beyond a single research project or
Professor Roy Crawford
institution. The connection among ARM, university research, and Belfast helped create an environment in which rotational molding could increasingly be studied scientifically rather than understood principally through accumulated shop-floor experience. That transition—from art toward science—was fundamental to the industry’s maturation. ARM’s investment in research was accompanied by growing technical education. A Speakers Bureau took rotational molding expertise to schools, plastics organizations, and other audiences. Technical manuals, seminars, videos, and meeting presentations multiplied. The Association was not only serving existing molders; it was working to expand awareness of the process among designers, students, and potential users. Meanwhile, the industry itself was changing visibly. During ARM’s second decade, rotational molding began shedding the perception that it was principally a process for tanks. Consumer products, toys, (Little Tikes already existed), kayaks, furniture, floor-care products, and point-of-purchase displays helped expose the process to broader markets. The number of rotational molding companies expanded rapidly. ARM expanded with them. By the late 1980s and early 1990s, the Association was holding meetings in locations including London, Toronto, Vienna, and Barcelona. Its international participation had grown significantly, and by 1992, ARM had approximately 350 member companies. That year, the Board concluded that the Association had grown large enough to employ its own staff. Charles D. Frederick was hired to manage ARM in 1987, and he retired in 2002. In 1991, the ARM Board of Directors, under the direction of ARM President Chuck Carlsen, and JSJ Productions, Inc. collaborated to launch a trade magazine for ARM. Rotation was launched to report on ARM’s companies, people, and products and on the technical advancements of the process. In 2005, Rotation became RotoWorld®, an independent magazine for the global rotational molding industry while maintaining a close relationship with ARM. Professor Roy Crawford served as the Technical Director of Rotation followed by RotoWorld® until his passing in 2016. Soon thereafter, Alvin Spence of Centro Incorporated was named RotoWorld® Technical Director. Ravi Mehra recalled: “It was in the 1990s that Dr. Roy Crawford really brought an explanation of the black magic process to all how it developed into a science. It was also through ARM that the international
www.rotoworldmag.com 31
scene began to develop. StAR was started in 2004; Rotopol was started in 2006; and Anipac in 2007 as divisions of ARM International. All three associations became independent over the next 3-5 years.”
An Industry Comes of Age
By ARM’s 20th anniversary in 1996, the numbers told an extraordinary story. From an initial roster of roughly 20 companies, ARM had grown to approximately 400 companies representing 56 countries. About 120 members served on 12 committees. Members could access nearly 300 papers and publications through the ARM Library, along with manuals, videos, and other training materials covering design, quality assurance, equipment, resin properties, troubleshooting, and manufacturing practices. ARM had fulfilled much of the mandate envisioned at its beginning: educating users, increasing awareness among designers, developing materials and product guidelines, providing technical seminars, and creating central sources of industry information, and global networking. But maturity brought new complications. During the Association’s third decade, other organizations were expanding their involvement in rotational molding. The Society of Plastics Engineers developed a rotomolding-focused division with access to academic and technical resources. Around the world, regional organizations were emerging to address local markets, languages, and needs. There was a Pan-European Conference which was Europe centric in the 90s, which became ARMO with a global focus in the early 2000s. Meanwhile, European organizations were developing the umbrella organization that became ARMO. These developments forced ARM to confront an important question: how could it remain a leader while an increasingly global industry developed multiple centers of expertise? The answer evolved over time. ARM ultimately refocused its organizational mission on North America while cooperating with independent rotational molding organizations internationally. In 2010, the Board dropped “International” from the Association’s name while continuing to work with ARMO and international partners. The distinction proved positive and important. ARM did not need to own every corner of the global rotational molding community to influence it. It could lead by contributing.
Rotoplas: Where the Industry Meets
Few ARM activities embody that role more visibly
32 ROTOWORLD® ISSUE 2 • 2026
than Rotoplas. Meetings had been part of ARM from the beginning, but the trade show component evolved into something larger: a place where machinery could operate on the exhibition floor, suppliers could introduce materials and technology, molders could compare solutions, technical papers could be presented, and relationships could form across company and national boundaries. Those relationships mattered. ARM member since 1976, Harry Covington, McNeil followed by Ferry Industries, was a strong supporter of Rotoplas. Harry said: “ARM’s international trade show provided the industry an opportunity for the molders and suppliers of the industry to come together at one time under one roof to showcase and share the latest technology in machines, molds, materials, and ancillary products. It allowed us to share our technology and ask questions. It also showcased our industry before the media.” In 2001, Rotoplas was scheduled only weeks after the September 11 terrorist attacks. Corporate travel collapsed, registrations disappeared, and ARM had to cancel an event that represented its largest source of revenue. With support from the industry and intensive work by ARM’s Board and staff, Rotoplas was rescheduled in Toronto the following year—and drew record crowds. It would not be the last time ARM had to adapt to events far beyond its control.
Resilience and Reinvention
The 2008 recession created another serious financial challenge. ARM canceled its spring meeting as member companies dealt with the economic downturn. The Association also changed its management structure, beginning a relationship with CM Services in 2007 that played an important role in ARM’s subsequent resurgence. Instead of simply restoring the old meeting model, ARM reconsidered what its members needed. CM Services managed the Association from 2007 – 2018. In 2009, the spring meeting became the Executive Forum, aimed at company leaders and suppliers and expanding beyond strictly technical subjects to business issues including safety, generational change, employee morale, and succession planning. Regional meetings aimed at shop-floor personnel provided another level of education. This was an important evolution. At the same time, technology was changing what happened inside those companies. Ravi Mehra said: “Internal air-temperature monitoring and the improved
understanding of heating and cooling was the most significant contribution from the RMDC at Queen’s University under Professor Roy Crawford’s leadership. PIAT is still the crux behind the process.” Machines became increasingly automated. Multi-axis CNC equipment and robotics became common in secondary operations. ARM’s educational delivery was changing as well. Technical knowledge that once required traveling to a meeting increasingly became available through websites, digital libraries, videos, and webinars. That transformation would become crucial.
From Meetings to Continuous Education
By the time ARM celebrated its 40th anniversary in 2016, it was again looking deliberately toward the future. Conchita Miranda, then beginning her first term as ARM President, highlighted the appointment of Dr. Nick Henwood as Technical Director. The position had been vacant for several years following Professor Roy Crawford’s tenure. ARM was also modernizing its website and social-media presence and investing in new member benefits from a position of improved financial stability. Education accelerated. ARM developed structured Operator Training covering the practical fundamentals of rotational molding. The program grew to more than eight hours of instruction and was subsequently paired with testing and translated into Spanish. The Roy Crawford Education and Development Foundation, founded in 2012, expanded its support of scholarships, education, and research. The progression proved significant. Early ARM members exchanged experience at meetings. Then ARM codified knowledge in manuals and publications. Later came videos, technical libraries, and seminars. Eventually, structured online training and certificate programs made education available to entire workforces. ARM was gradually building something resembling an industry curriculum. And then, in 2020, the world stopped traveling.
When the Doors Closed, ARM Stayed Open
COVID-19 struck directly at one of ARM’s traditional strengths: bringing people together. The Association responded by moving aggressively online. ARM’s first virtual meeting was rated as meeting or exceeding expectations by 98 percent of attendees, and the format exposed people to ARM programming who might not otherwise have incurred the cost of travel. At the same time, members made clear that technology
could not fully replace the face-to-face relationships at the heart of the Association. What could be replaced— and dramatically expanded—was access to education. In 2018, Adam Webb and Anna Singer, Webb Evans & Associates, were hired to manage the Association and continue to do so today. It was a seamless transition as Adam Webb had been managing ARM since 2008 under CM Services. During 2020, ARM added 32 webinars, taking its on-demand library beyond 100 videos. Webinar views reached 10,000 for the year, twice the 2019 level. More than 50 suppliers participated in a virtual exhibit experience, and supplier videos generated thousands of views. The pandemic closed meeting rooms, but ARM’s educational reach grew. It also gave the Association and its members an opportunity to consider where the industry was heading. A North American industry SWOT analysis examined rotational molding in the context of Industry 4.0 and identified opportunities in automation, conversion from other materials and processes, new polymers, and increased awareness among OEMs and designers. It also confronted labor shortages, resistance to automation, competition from other plastics processes, rapidly advancing additive manufacturing, and environmental pressures. When members returned to Rotoplas in 2021, they returned to an industry that had changed. Automation, robotics, alternative materials, and new technologies were increasingly prominent. ARM’s 2022 theme, “Creating Efficiencies,” reflected the new environment while programming expanded into logistics, scheduling, entrepreneurship, and employee retention. ARM did not simply go back to what it had been before COVID. It emerged with more ways to serve its members.
Training the Next Generation
That expanded educational role has become one of ARM’s defining modern accomplishments. Operator education was joined by training in finishing, design, health and safety, wall-thickness control, and other subjects. Certificate programs gave companies a structured way to develop employees. Technical webinars allowed a specialist’s knowledge to reach a plant hundreds or thousands of miles away. The Roy Crawford Education and Development Foundation reinforced another part of that mission by supporting scholarships, education, and research. ARM also continued to invest in students and younger members through design competitions,
www.rotoworldmag.com 33
L-R: Dave and Brenda Smith; Paul Nugent; Tom Innis and Conchita Miranda; Chris Lefas; John Steele; Marilyn Wade; Celal Beysel; Steve Copeland; Nick Henwood and Gareth McDowell, Ron Cooke and Horacio Lobo; Shivinder Chawla; Jim Leitz; Larry Whittemore; and Corey Claussen and Mike Dorsey 34 ROTOWORLD ISSUE 2 • 2026 ®
Later Years!
L-R: Jim Hummel; Brian Olesen and Bill Spenceley, ARM Hall of Fame; Harry Covington; Brandi Howard; Einar Voldner, Adam Webb and Anna Singer; Pat and Beth Long, Manju Mehra, and Tommie Niland; Alvin Spence; Rotoplas Ribbon Cutting Team www.rotoworldmag.com 35
educational outreach, and programs intended to bring a new generation into the Association. That matters because one of ARM’s greatest resources has never appeared on a balance sheet. It is accumulated experience. Past President Alvin Spence remarked: “As one of Roy’s research students before joining Centro, Inc., I saw firsthand his passion for research and sharing knowledge. As ARM’s Technical Director, Roy inspired generations of rotomolders to apply science and technology to improve processes and product quality. ARM continues this legacy through conferences, webinars, training, and other technical resources that connect members with current industry knowledge. Just as importantly, ARM has fostered a strong community where members build lasting relationships and exchange ideas, creating invaluable opportunities to learn from one another and stay at the forefront of industry technology.”
Research, Data and the Modern Process
The Association’s research role has also continued to evolve. ARM-supported studies have examined pigments, materials, process behavior, and other practical questions. Technical leadership increasingly emphasizes data over assumption— testing ideas rather than relying solely on conventional wisdom. That is especially important as rotational molding enters a period shaped by sustainability demands, recycled materials, process efficiency, automation, and digital manufacturing. The same industry that once relied heavily on an operator’s eye and experience is now incorporating sensors, analytics, process-control systems, robotics, simulation, and increasingly sophisticated design tools. Yet the fundamental question ARM asks remains remarkably similar to the one its founders faced: What does the industry need to know next, and how can we learn it together?
A Worldwide Community
The scale of the community ARM helped build was unmistakable at Rotoplas 2024. Nearly 1,000 attendees from 36 countries came together with 80 exhibitors—an extraordinary contrast with the small group that gathered in Chicago in 1976. But size alone does not explain ARM’s longevity. Ravi Mehra said: “Now the world has become smaller. We are entering the next stage of information, AI, recycling, and sustainability. We will see over the next 4-5 years major actions in the ways AI will be used for
36 ROTOWORLD® ISSUE 2 • 2026
Conchita Miranda, ARM President
process and quality control and how rotational molding will have an even bigger future. ARM is still leading the charge in many ways and is positioned to maintain that leadership for the future.” The Association’s long-running “What’s Your Problem?” discussions may be the purest expression of ARM’s culture. Members bring actual problems to other molders, suppliers, and experts and ask for help solving them. The format has survived changing technologies because the principle behind it remains useful. Someone else may already know the answer.
ARM at Fifty
The Association entered its anniversary year as an organization still adding programs and asking new questions. During the half year alone, ARM expanded its Training Academy with a six-part rotational molding design webinar series, launched Portugueselanguage operator training, continued machinesafety education, and began Process Optimization Committee studies examining melt-index comparison and the relationship between mold geometry and powder distribution.
Members now have access to more than 125 on-demand webinars, multiple online certificate programs, classic training videos with Spanish subtitles, troubleshooting calls, and more than 700 documents and presentations from past Annual Meetings. The technology may be new, but the mission is recognizable. Current ARM President Conchita Miranda has identified three priorities for the anniversary year: funding relevant technical research, using AI and ARM’s redesigned website to provide more personalized member service, and celebrating the 50th anniversary throughout 2026. There is historical resonance in one of those celebrations. Conchita said: “Fifty years is a long time for any association to survive. ARM has not only survived, but we are also still growing. We show up for each other. We share what we know. That is what has kept ARM alive for fifty years and is what will carry us forward. I hope you will join us in New Orleans this November to celebrate what we have built together. If you have been part of this industry for decades, come and reconnect. If you are newer to rotomolding, come and see what this Roto Family is all about. Either way, you belong here.” ARM’s 2026 Executive Forum returned to Belfast and Queen’s University; a place deeply connected to the Association’s research history and to the legacy of Professor Roy Crawford. The program itself illustrates how far the technology has traveled: sensor integration, data analytics, digital twins, simulation, automated resin dispensing, part ejection, process control, design, and cooling research. From the Rotomolding Development Center and Professor Crawford’s pioneering research to digital twins and real-time manufacturing data, there is a remarkable continuity. ARM keeps bringing the industry to the next question. And in November, Rotoplas 2026 in New Orleans will provide the setting for the Association’s 50th Anniversary Annual Meeting—a gathering that will celebrate not only an organization but the thousands of people who have built it.
The Catalyst
Fifty years of history inevitably produces a long list of presidents, directors, committee chairs, staff members, technical experts, educators, molders and suppliers. Some became industry legends. Many worked quietly. ARM’s history belongs to all of them.
It belongs to early leaders willing to put money behind an organization whose future was uncertain. To people like Glenn Beall, who helped turn scattered knowledge into practical design guidance. To Ravi Mehra and those who believed rotational molding needed serious research. To Professor Roy Crawford, whose influence on the technical development of the process reached across generations and continents. To the many educators and technical leaders who followed. To suppliers who brought materials, machinery, and expertise to the table. To volunteer boards and committees that kept asking what members needed next. And it belongs to the companies that were willing to let their people sit down with competitors and share knowledge and discuss problems. That may be ARM’s most consequential achievement. The Association did not invent rotational molding, and no association can claim responsibility for the ingenuity of an entire industry. The advances of the past 50 years came from thousands of individuals and companies—molders, machine manufacturers, material suppliers, moldmakers, designers, researchers, educators, and entrepreneurs. But ARM gave those people a place to meet. It gave their knowledge a structure. It gave their research an audience. It gave innovation a showcase. It gave new generations a place to learn from those who came before them. And repeatedly, when the industry faced a new technology, a new economic reality, a new market, or a new problem, ARM brought people together to figure out what came next. In her 2026 anniversary message, Conchita Miranda looked back to the companies that gathered in Chicago and forward to the worldwide community ARM has become. Her description of ARM’s continuing strength is simple: members continue to show up, share, and treat competitors like family. That spirit was visible in 1976. It is still visible in 2026. The machines are different. The materials are better. The science is deeper. The products are more complex. The industry is global, and the next generation of rotational molding will increasingly be shaped by automation, data, sustainability, advanced materials, and artificial intelligence. After 50 years, ARM’s fundamental contribution remains surprisingly constant. It brings the people who can advance rotational molding together—and gives them a reason to advance it together. That is more than an association’s history. It is ARM’s legacy. R
www.rotoworldmag.com 37
AT I SS U E
ALDO QUARATINO Matrix Polymers
Advancing Materials for the Future of Rotational Moulding Materials Innovation will Define the Industry’s Future
One of the greatest opportunities facing the rotational moulding industry today lies in the development of advanced engineering polymers specifically designed for the process. Unlike many plastics processing technologies, rotational moulding operates without applying pressure to the material during production. While this characteristic offers unique design and manufacturing advantages, it also limits the range of polymers that can be processed successfully. For material suppliers, however, this challenge presents a significant opportunity to innovate. By advancing polymer chemistry and material design, the industry can expand the portfolio of materials available to rotational moulders beyond traditional polyethylene. This evolution has the potential to unlock entirely new applications, improve product performance
38 ROTOWORLD® ISSUE 2 • 2026
and enable moulders to compete in sectors that were previously inaccessible.
Beyond Polyethylene: Expanding the Material Toolbox While polyethylene remains the material of choice for rotational moulding, its long-standing success is founded on a proven combination of processability, durability, and cost-effectiveness. However, market demands continue to evolve. Industries increasingly require materials capable of delivering enhanced chemical resistance, greater mechanical strength, improved thermal stability, and superior long-term performance. Engineering polymers such as Polyamide 6 (PA6), acetal, and fluoropolymers offer the potential to meet these requirements. The challenge lies in adapting these materials to perform reliably within the unique constraints of the rotational moulding process.
Successfully doing so would provide moulders with access to higher-value applications and create opportunities to enter markets traditionally served by alternative manufacturing technologies.
Unlocking Opportunities in the Energy Sector
The energy sector provides a compelling example of where advanced materials can create new opportunities for rotational moulding. As investment in hydrogen infrastructure, industrial gases, and alternative fuel technologies accelerates worldwide, demand for advanced storage and transportation solutions continues to grow. Rotational moulding is increasingly being adopted to manufacture internal liners for Type IV pressure vessels, which are subsequently reinforced with carbon fibre composites capable of safely containing
AT I SS U E
pressures of up to 750 bar. These developments highlight the growing role that advanced polymer materials can play in supporting the transition towards cleaner energy systems and next-generation transportation technologies. This market is already experiencing strong growth. Industry forecasts suggest the global Type IV hydrogen pressure vessel market could grow from approximately $700–800 million today to more than $1.2 billion by 2032. As these applications develop, material performance becomes increasingly critical. Engineers and manufacturers must consider factors such as long-term creep resistance, gas permeability, chemical compatibility, and overall service life. Meeting these requirements will require close collaboration between material suppliers, moulders, and end users.
Meeting the Demands of Modern Transportation
Transportation has long been one of the most important markets for rotational moulding. Fuel tanks, hydraulic reservoirs, air ducts, mudguards, dashboards, and agricultural vehicle components have all been successfully produced using rotational moulding for many years. However, evolving environmental regulations and increasingly demanding performance standards are changing market expectations. Future applications will require materials capable of withstanding harsher operating environments while maintaining long-term
durability and performance. Increased exposure to chemicals, elevated temperatures and mechanical stress will continue to challenge conventional material solutions. To remain competitive, the industry must continue to invest in materials that can meet these evolving requirements.
Polyamide 6: A Case Study in Materials Innovation
Polyamide 6, commonly known as Nylon, is one of the most interesting examples of both the challenge and opportunity facing the rotational moulding industry.
“INDUSTRY FORECASTS SUGGEST THE GLOBAL TYPE IV HYDROGEN PRESSURE VESSEL MARKET COULD GROW FROM APPROXIMATELY $700-800 MILLION TODAY TO MORE THAN $1.2 BILLION BY 2032.”
Although widely used across engineering applications, PA6 remains one of the most difficult polymers to process through conventional rotational moulding techniques. Its naturally high
viscosity, sensitivity to moisture, and susceptibility to thermal degradation create significant processing challenges. As a result, moulders often rely on specialised techniques such as inert atmospheres, cooling agents, and heavy pigmentation to achieve acceptable results. While these approaches can be effective, they add complexity and cost to the manufacturing process. The industry should not have to rely on workarounds.
Engineering Materials Specifically for Rotational Moulding
Through careful polymer selection and advanced material engineering, it is possible to develop Polyamide 6 grades specifically designed for rotational moulding. Achieving this is far from straightforward. It requires extensive expertise in polymer chemistry, processing behaviour and powder manufacturing technology. Producing a consistent, reliable powder that performs effectively across different rotational moulding machines and operating conditions represents a significant technical achievement. Yet these innovations are essential if the industry is to expand the range of applications that can be successfully manufactured through rotational moulding. By developing materials around the process, rather than adapting the process around the material, suppliers can help remove barriers to adoption and accelerate industry growth.
www.rotoworldmag.com 39
AT I SS U E
Creating New Markets Through Collaboration
A Call to Innovate
The future of rotational moulding will depend on collaboration across the entire value chain. Material suppliers, moulders, machine manufacturers, designers, and end users all have a role to play in identifying emerging opportunities and overcoming technical challenges. Together, the industry can develop solutions that not only meet current requirements but also anticipate future market demands. Innovation in materials has the potential to transform the scope of rotational moulding and expand its relevance in sectors that demand increasingly sophisticated performance characteristics.
As material suppliers, our responsibility extends beyond supporting today’s applications. We must also help enable the next generation of rotationally moulded products. By investing in advanced engineering polymers tailored specifically for rotational moulding, the industry can access new markets, meet future regulatory requirements, and unlock opportunities via technical solutions that were previously beyond reach. The future of rotational moulding will not be defined solely by the products we manufacture, but by the materials that make those products possible. The
opportunity is clear. The challenge now is to continue innovating and ensure that rotational moulding remains a competitive and relevant manufacturing technology for decades to come. R
ROTOMOULDING SOLUTIONS + PROBLEM
= UNDERSTANDING
SOLUTION
I help organisations around the world solve real rotomoulding problems and improve their operational performance and effectiveness. My knowledge is built around 40 years of real life experience working within the rotomoulding industry, as a supplier, as a moulder and now as an independent consultant. For more information contact ianhansenconsult@gmail.com or www.ianhansenconsult.com
40 ROTOWORLD® ISSUE 2 • 2026
www.rotoworldmag.com 41
Lower Temperatures, Higher Productivity: Flexahopper Saves Energy with NOVAPOL® TRx Resin Dave Sullivan, Technical Service Specialist at NOVA Chemicals
On the path to building a more circular economy for plastics, rotomolded products offer a variety of benefits. Rotomolded tanks and containers are known for their long service life, durability, and ability to withstand repeated reuse. High density polyethylene (HDPE) requires less energy to process than fiberglass or steel, and has a lower material carbon footprint. Additionally, HDPE tanks and containers offer inherent corrosion resistance, making them well suited for applications ranging from water and chemical storage to agricultural and industrial handling. From a product utilization standpoint, rotomolded components stay in use for many years with infrequent replacement. However, on the production side, the rotational molding process can be energy intensive. Rotational molding relies on controlled heating and cooling steps that require significant thermal input and air movement. As a result, rotomolders face ongoing pressures to reduce energy consumption and shorten cycle times without compromising part performance. Multiple strategies can help improve process efficiency. Some
42 ROTOWORLD® ISSUE 2 • 2026
involve equipment or operational adjustments such as adding or repositioning molds, coordinating machine scheduling to minimize idle heating, or adopting more precise temperature control. Beyond process changes, the choice of rotational molding resins offers another potential avenue for maximizing efficiency and reducing costs. Resins designed to achieve good cure at lower temperatures can reduce the total thermal load of each
cycle, offering the potential to simultaneously cut energy use and improve throughput. Flexahopper Plastics Ltd. is a Canadian rotomolder known for its forward thinking approach to sustainability. Flexahopper recently partnered with NOVA Chemicals to test the energy savings and productivity capabilities of NOVAPOL® TRx resin. This article describes how this partnership resulted in savings of 30% on cycle time
TECHNICAL FEATURE
and energy use for thick-walled chemical storage tanks, achieving good cure with significantly less energy use than a traditional hexene resin.
Collaboration for Circularity
Headquartered in Lethbridge, Alberta, Flexahopper is an industry leader in sustainable production practices. The company sources renewable power through its solar array and green energy purchasing contracts and is also developing electric mold heating technologies. Flexahopper’s long-term goals include reducing the company’s carbon footprint while improving the efficiency and reliability of rotomolding processes. Material selection is also part of Flexahopper’s process optimization equation. A resin capable of achieving cure at lower temperatures can reduce energy demands and ease the thermal load on cooling stations, but resins with lower processing temperatures like TRx must also meet performance and quality requirements. NOVA Chemicals, a supplier of polyethylene (HDPE, LLDPE, and LDPE) and recycled polyethylene (rPE) resins, also focuses on developing products and processes that support plastics circularity. NOVAPOL® TRx resins were specifically developed to process at lower temperatures and offer broader processing windows than traditional hexene rotomolding resins, helping rotomolders lower cycle times and increase operational flexibility.
The chemistry of the TRx resin helps the PE powder coalesce faster in the mold by promoting quicker bubble removal as the powdered resin melts. This improves sintering, which is the stage where individual powder particles soften, fuse together, and air bubbles diffuse out so the polymer wall becomes a continuous, bubble-free melt layer. As Dr. Nick Henwood (ARM Technical Director) has described in his work on sintering, good sintering behavior is critical to achieving full fusion without overcooking the part. TRx delivers this improved sintering and helps avoid over-curing. With a common goal of making rotational molding more energy efficient, NOVA Chemicals and Flexahopper collaborated to run laboratory tests and full scale manufacturing trials on TRx resins.
The Value of Lower Temperature Processing
In rotational molding, the cooling phase contributes the largest share of the overall cycle time and therefore often represents the primary bottleneck for faster manufacturing. The thermal mass of the polymer and mold determines how long it takes for a part to cool sufficiently for demolding without warpage, and a higher PIAT means cooling will take longer. In other words, a lower PIAT means shorter cooling cycles. With TRx resins, there is a significant opportunity to reduce cooling times by optimizing the cooking cycle to lower PIAT.
If a resin can achieve good cure at a lower temperature, ovens will use less energy for heating, cook times will shorten, and the cooling process will take less time. However, lower the temperature too far, and the part risks undercuring, with bubble formation that compromises the impact strength and integrity of the part. Lower temperature resins must be able to successfully eliminate bubbles quickly and deliver the required as-molded density. Multiple field trials have demonstrated TRx’s ability to meet these requirements.
Good Cure and Why It’s Important
When impact resistance is a key performance requirement for rotationally molded parts, good cure is critical. Parts that are under-cured or over-cured typically behave in a brittle manner, where cracks propagate beyond the impact zone rather than remaining localized. This increases the risk of shattering or impact related failure. Impact performance is commonly evaluated using the ARM Impact Dart Test. In this method, a weighted dart is dropped from defined heights (laddering up and down around the failure point) onto a molded part conditioned to a target temperature, often −40°F. The test determines mean failure energy (MFE) and ductile versus brittle behavior. When good cure is not achieved, ARM ductility is often low (for example, <50%) and failures are more likely to be brittle.
www.rotoworldmag.com 43
TECHNICAL FEATURE
Laboratory Trials: Thin-Walled Cubes
Laboratory trials were conducted at NOVA Chemicals to evaluate the energy savings potential under two processing strategies: reduced oven temperatures and reduced cycle times. Trials began with 8 lb cubes with 1/4” wall thickness, which were designed to evaluate TRx in laboratory conditions. The objective was to compare TRx directly to a standard hexene resin under two
Cycle Time Savings Gas Consumption (ft3)
1,250
13 runs
1,200 1,150 1,100 1,050 1,000
1,219 cu ft
13 runs
1,055 cu ft
950 900
Baselines
Reduced Cycle Times 19%
Figure 1(a): Cycle Time Savings
Reduced Oven Temps 1,300 1,250
13 runs
1,200 1,150 1,100 1,050 1,000
1,219 cu ft
950
13 runs 975 cu ft
900
Baselines Figure 1(b) : Reduction in Oven Temp
44 ROTOWORLD® ISSUE 2 • 2026
scenarios: shorter cycle times at the same oven temperatures, and lower oven temperatures with comparable cook times. When production output was held constant at the baseline of 13 runs per shift, TRx reduced natural gas usage by 13.5%, with a 19% reduction in cycle time (see Figure 1a). When the focus was on reduced oven temperatures, natural gas usage fell by 20% (see Figure 1b).
1,300
Gas Consumption (ft3)
On the shop floor, molders assess cure state by examining bubble content in a part cross section. A small amount of bubbles, located near the inner wall, is often used as a practical indicator of good cure. Excess bubbles suggest under-cure, while a completely bubble-free cross section may indicate over-cure. Although TRx resins can accommodate a true zero bubble state across the part cross section while still maintaining strong impact performance (meaning the resin does not immediately transition into an over-cured condition once bubbles disappear), this creates a practical challenge for molders. When bubbles are no longer visible, visual indicators distinguishing good cure from over-cure are lost. Additionally, for fair comparisons between traditional hexene-based resins and TRx materials, NOVA typically targets a similar visual bubble state during field trials, followed by optical microscopy in the lab to confirm bubble condition. Microscopy results are then correlated with ARM impact performance and as-molded density measurements to verify that TRx parts were processed under appropriate conditions to achieve good cure. A key advantage of TRx technology is its ability to achieve good cure at significantly lower PIAT by promoting faster bubble removal and improved sintering behavior. This allows molders to reduce heat input while maintaining strong impact performance and achieving more efficient cycles.
Reduced Oven Temps 7%
Lower Temperatures, Higher Productivity: Flexahopper Saves Energy with NOVAPOL® TRx Resin
Real-World Manufacturing Trial #1: Standard Walled Thickness Tanks
Trials using a standard wall thickness (3/16”) were conducted to demonstrate that TRx could reduce cycle time and energy
16 runs
1,300
Gas Consumption (ft3)
To test output capacity, the research team measured how many parts could be made during an 8-hour shift while maintaining the cure quality of the baseline traditional resin. Running TRx resin with reduced cycle times allowed for 16 runs and a 13.5% gas savings per run compared to the baseline. When the priority shifted to lower oven temperatures, TRx supported 14 runs with energy savings of 20% per run. The trials demonstrated that molders could choose the optimization strategy that is most aligned with their operational goals. If the molder has labor constraints and cannot make more parts, then lower oven temperatures can help save energy while maintaining the production rate. If increased production is required to meet a high order demand, then the molder could reduce cycle time to make more parts per shift. In either case, cooling time is reduced, giving operators additional time at demolding/ loading to maintain the indexing schedule, which can be difficult when a carousel is running parts with a variety of mixed cycle times. Laboratory trial data showed that when 8-lb, 1/4” test cubes are produced to capacity during an 8-hour shift, TRx delivers higher output with lower energy consumption per part compared to the traditional hexene baseline resin (see Figure 2).
1,250
13 runs
1,200 1,150 1,100 1,050 1,000
1,298 cu ft
1,219 cu ft
14 runs
1,050 cu ft
950 900
Baselines
Reduced Cycle Times 19%
Reduced Oven Temps 7%
Figure 2: Maximum Part Production in an 8-hour Shift
Figure 3: Comparative Bubble Content for Traditional Hexene v TRx at a Lower PIAT
Figure 4: ARM Dart Impact MFE and Ductility Comparison
consumption while delivering equivalent or improved impact performance. These evaluations were performed prior to the thickwalled tank trials because the 3/8” wall thickness exceeds the practical limits of the ARM impact test. The selected part was a 225 gallon leg tank at 3/16” wall thickness. A reference tank was first produced using the traditional hexene resin, and its cook time, PIAT, and natural
gas consumption (cu ft) were recorded. Cure state was verified through sidewall cutouts, confirming only minor bubble presence within the crosssectional area (see Figure 3). A comparable TRx leg tank was then produced by reducing cook time by 5% and verifying that a near equivalent good cure state was maintained. The resulting TRx part achieved a 17% reduction in overall cycle time while
www.rotoworldmag.com 45
TECHNICAL FEATURE
maintaining equivalent demolding temperatures. This demonstrates the impact that lower PIAT can have on shortening cooling time and accelerating overall manufacturing throughput. The traditional material required a PIAT of 353°F, whereas TRx produced equivalent parts at approximately 335°F, which equated to an 18°F reduction in PIAT corresponding to a 22% reduction in energy consumption. ARM impact testing performed on sidewall cutouts showed equivalent or slightly improved performance for TRx despite the lower PIAT and 17% faster cycle time (see Figure 4).
Figure 5: 3/8” Thick-Walled Tanks Used in the Production Trial
Real-World Manufacturing Trial #2: Thick-Walled Tanks Flexahopper produces many kinds of tanks and containers of different thicknesses. For the production trials using TRx the team selected a 285 lb tank with a 3/8” wall thickness. Thick-walled parts retain heat longer and are more susceptible to warpage if cooling occurs too quickly. These tanks represented a demanding use case with long heating and cooling times which made them ideal candidates for testing the energy saving advantages of TRx. The goal was to reduce natural gas consumption while increasing output, maintaining part quality, and achieving proper cure at a lower PIAT than the traditional hexene resin. Processing included the established conditions used with the traditional hexene resin, reduced oven temperature conditions, and reduced cycle times to test how the new resin would affect operations and product quality. Process
46 ROTOWORLD® ISSUE 2 • 2026
Figure 6: PIAT Comparison for Traditional Hexene v TRx with Equivalent Cure
measurements compared oven temperatures, cook times, cooling times, and PIAT. The team assessed bubble formation and measured
as-molded density, providing an objective metric for determining whether TRx resins produced an equivalent or better cure state.
Lower Temperatures, Higher Productivity: Flexahopper Saves Energy with NOVAPOL® TRx Resin
In the reduced cycle time conditions, results showed that TRx resin reached an improved cure state (with a higher as-molded density) at significantly lower temperatures than the traditional hexene resin. With a PIAT of 321°F, TRx resin demonstrated a 55°F lower peak temperature than the traditional resin (see Figure 6). Natural gas consumption dropped by 163 cu ft per part, from 554 to 391 cu ft. TRx also reduced cook times by nearly 15 minutes and cooling time by 26 minutes. To prevent warpage, the team used air-only cooling for the trials, but the cooling times could be reduced even further with the addition of water cooling. TRx produced parts with as-molded densities at or above 0.938 g/cc, whereas the traditional material, which had the same target density, only reached 0.930 g/cc (see Figure 7). The
Figure 7: Molded Density Comparison for Traditional Hexene v TRx with Equivalent Cure
When using reduced oven temperatures to focus on energy savings, TRx achieved its target PIAT of 326°F with oven temperatures of 500°F, compared to the 552°F baseline. The lower PIAT provides opportunities to reduce cooling time across both the reduced oven temperature and the reduced cycle time
These findings demonstrate an opportunity to reduce operating costs and carbon footprint without additional capital investment. By changing materials, rotomolders can realize savings with their existing equipment. Cook times were also reduced by 30%, allowing manufacturers to produce more parts in the
Material
Condition
Shot Weight (lbs)
Cook Time (min)
Oven Temp (ºF)
Cool Time (min)
PIAT (ºF)
Traditional hexene
Baseline
285
38
552
75
376
TRx0338-U
Reduce Oven T
285
38
500
60
326
TRx0338-U
Reduce Cycle T
285
23.5
550
49
321
Table 1: Cycle Time and Oven Temperature Processing Benefits Offered by TRx Resin
lower as-molded density indicates the part was less cured (more bubbles). Sidewall microscopy showed that TRx parts showed fewer small bubbles at the lower PIAT value, demonstrating a better cure with the lower temperature, whereas the parts made with traditional resin grade showed many larger bubbles.
operating conditions (see Table 1). The commercial scale trials confirmed initial lab results, demonstrating that TRx resin can significantly reduce energy use and cycle time while maintaining part quality. By achieving good cure at much lower internal air temperatures, TRx lowered natural gas consumption by 30%.
same timeframe. Despite lower temperatures and faster cycles, TRx consistently delivered an equivalent cure. If a molder experiences a spike in orders, the faster cycle times can enable increased manufacturing capabilities to meet customer needs. For custom rotomolders, TRx resin could also open the door to new product
www.rotoworldmag.com 47
TECHNICAL FEATURE
offerings with the higher production capacity and increased machine time availability. Overall, these results show that TRx resin provides a combination of energy savings, productivity gains, and reliable performance across real-world manufacturing conditions.
Supporting Efficiency and Sustainability
As a result of these trials, Flexahopper decided to implement TRx resin with the reduced cycle time processing conditions. These material and process modifications will help the company make more tanks in less time. The improvements also closely align with Flexahopper’s
48 ROTOWORLD® ISSUE 2 • 2026
commitment to sustainability. The combination of material innovation and the willingness to embrace change creates a more efficient process with economic and environmental benefits. The partnership between Flexahopper and NOVA Chemicals offers a model for how rotomolders can approach process innovation. By combining resin engineering and real-world production trials, the two companies shared their expertise in material science and processing excellence to deliver substantial energy savings without sacrificing performance. As sustainability targets continue to shape manufacturing practices, resins designed to cure at lower temperatures could
play an increasingly important role. Resin technologies, such as TRx, enable rotomolders to choose their main priority for manufacturing, whether that is maximizing output or reducing energy consumption and cost. These trials demonstrate the availability of different levers for achieving those goals alongside machinery settings and operational controls. The choices and paths to achieving improvement are ultimately up to each molder.
Footnotes: 1. In March, 2026,
NOVA Chemicals Corporation was acquired by Borouge Group International AG to establish Borouge International. R
ARM Executive Conference Belfast LOCKDOWN IN BELFAST!
June 9th – 11th Alvin Spence, Centro Incorporated
AMIC SERVES AS A ‘FACTORY OF THE FUTURE,’ CONNECTING ACADEMIC RESEARCH WITH INDUSTRY TO ACCELERATE INNOVATION. Queen’s University Advanced Manufacturing Innovation Centre (AMIC)
Hosting an ARM conference at Queen’s University Belfast was a dream come true for several of us who are Queen’s alumni. Unfortunately, events outside our control meant the dream did not unfold quite as planned. On the evening of June 9th, following our initial plant tours of Kingspan and Collins Aerospace, reports of a violent incident began circulating through local news outlets. By the next day, social media activity had intensified, and protests were being called for on the streets of Belfast. Concerned for the safety of their employees, many local businesses chose to close early on June 10th, and Queen’s University made the same decision. As a result, our planned venue, Riddel Hall, was no longer available.
The ARM staff responded quickly, assessing options that would allow the conference to continue in a location that was both safe and functional for the presentation portion of the program. Fortunately, the Grand Central Hotel, where most delegates were staying, came to our rescue by providing the necessary Conference Dinner room and facilities. That evening, many attendees could see fires from gallery. For several of us who lived burning buildings, cars and buses through the 1970s, 1980s, and across the city from the safety 1990s, it brought back memories of of the hotel’s 23rd floor viewing “The Troubles.” Queen’s University
www.rotoworldmag.com 49
remained closed on Thursday, June 11th, which meant we were also unable to use Riddel Hall or the Great Hall, where our closing dinner had been planned. Once again, the conference hotel stepped up and saved the day, allowing all planned presentations, lunches, and dinners to take place as scheduled.
Factory Tours June 9th-10th
Despite the local unrest, the factory tours were able to proceed as planned. On Tuesday morning June 9th, the North American delegates traveled by bus to Kingspan Water & Energy Limited, located just outside Portadown, Northern Ireland. Kingspan is one of the largest rotational molders in Europe, producing a broad range of proprietary and custom molded products. The company operates globally, with more than 29,000 employees and annual sales exceeding €9 billion. Under its Titan brand, Kingspan is recognized as a global leader in energy storage solutions, designing and manufacturing innovative systems
Delegates examine a rotomolded storage tank during a factory tour.
for storing and dispensing diesel, DEF (AdBlue), oil, and fertilizers. The company also manufactures tanks and containers for commercial, industrial, agricultural, and domestic markets. In addition, Kingspan offers sustainable wastewater, rainwater, stormwater, and potable water solutions for residential, commercial, and industrial applications, supported
ARM delegates visit Kingspan Water & Energy Limited.
50 ROTOWORLD® ISSUE 2 • 2026
by expert servicing and real-time monitoring. Its custom molding capabilities include fuel and DEF tanks for agricultural and construction vehicles. In the afternoon, the North American delegates traveled to the small seaside town of Kilkeel, County Down, to tour Collins Aerospace, a leader in lean manufacturing. The Kilkeel site produces aircraft seating and furniture for global aircraft manufacturers, including business class, premium economy, and economy seating. In fact, Collins Aerospace has manufactured approximately 25% of all aircraft seating currently in commercial use today. The site also includes thermoforming operations for advanced materials, along with precise CNC trimming capabilities. Its primary activity, however, is the assembly of aircraft seating, where the team has specialized in “U” shaped workcells with products
flowing in a counterclockwise direction. The main assembly building includes 15 individual workcells and employs more than 1,000 local people. With strong order backlogs, the site places significant emphasis on takt time and rapid response to any line stoppage, since lost production capacity is especially costly. Product quality was clearly a top priority, with finished goods 100% inspected and approved before shipment. Although floor access during the tour was limited, it was evident that assembling these products is highly complex due to the number and variation of components involved, particularly in business class seating, which includes integrated electronics. On the morning of June 10th, the North American delegates traveled to the small town of Moira, on the outskirts of Belfast, to tour Clarehill Plastics. Founded in 1981, Clarehill has primarily focused on manufacturing oil storage tanks under the “Harlequin” brand. These types of tanks are used for oil-fired heating systems, which remains one of the primary methods for heating homes and domestic water in the UK. In recent years, Clarehill has expanded its product portfolio to include wastewater treatment tanks, rainwater harvesting tanks, and DEF (AdBlue) tanks. The Harlequin brand is well known throughout Ireland and the UK, and the company also manufactures a limited number of custom products. The tour provided delegates a close look at Clarehill’s material handling systems, manufacturing machines, and finishing and assembly areas.
Day 1 Conference Proceedings On the afternoon of June 10th, conference delegates gathered
for the first series of formal presentations. The opening session featured a panel discussion on how Queen’s University became rotomolding’s research home. Paul Nugent, Mark Kearns, and I reflected on our time at the University and what it was like to be there when Roy Crawford was such an influential figure in the industry. Paul spoke about the early days in the late 1980s, when Roy was beginning his journey into rotational molding. At that time, Queen’s did not yet have a rotational molding machine, and general information about the process was limited. This led to months of library research as Roy and his team worked to build knowledge and develop new ideas. Eventually, a machine was secured, and the practical work that followed led to the discovery of the internal air temperature profile. During my time at Queen’s in the 1990s, we benefited from having real industrial processing equipment and excellent technician support. Roy was becoming increasingly well known throughout the industry and was attracting both government and industry research funding. Rotational molding research grew rapidly at Queen’s during the 1990s, and Roy may have had four or five Ph.D. students, along with several master’s students, working on research projects at any given time. It was a remarkable period to be part of the program, culminating in the creation of the Rotational Moulding Research Centre in 1995, and the launch of several handson training courses beginning around 1996. Mark then spoke about the continuation of rotational molding research at Queen’s after Roy moved to New Zealand in the early 2000s. He described new partners and sponsors, as
well as technologies such as “Robomould,” which the University has researched extensively. I believe that if Roy were still with us today, he would have been very proud to hear and reflect on the contributions Queen’s University has made to the industry over the past 40 years, since he first fell in love with the process. Next, Ronny Ervik explored how European regulations and circular design principles are reshaping rotomolding and why these changes will affect every molder’s competitiveness. He noted that Europe generates nearly 32 million tonnes of plastic waste each year, that plastic accounts for approximately 80% of all marine litter, and that 87% of Europeans are concerned about the environmental impact of plastics. In response, the EU has developed environmental and plastic waste strategies, including a goal to reduce greenhouse gas emissions by 55% by 2030. Plastics are expected to face increasingly strict requirements, with the Packaging and Packaging Waste Regulation (PPWR), for example, requiring 10% recycled content by 2030. Transportation packaging also has a target of 40% reusable content by 2030. Because packaging regulations define plastic packaging broadly as materials used for the containment, protection, handling, delivery, and presentation of products, these requirements could apply to a wide range of rotomolded products. Larry Whittemore of Stoner, Inc. then shared his extensive experience explaining why rotomolded parts can develop a fuzzy or whitened appearance and how this issue can be prevented. He began by emphasizing several
www.rotoworldmag.com 51
fundamentals, including the importance of matching the correct release system to the resin being used. Once the appropriate system has been selected, proper application to the mold becomes critical. For best results, the mold should be clean and preheated before the release system is applied. The release coating should then be baked onto the mold by running it through an oven cycle without resin. Larry explained that the fuzzy or white appearance is often caused by the part sticking to the mold surface. To minimize this issue, molders should agitate the release agent before use, apply it with a fine spray, ensure an even coating, wipe away excess release with a clean cloth, and avoid overheating the mold during processing. Nick Henwood then explored the case for and against dry color, a topic of particular interest given the long-standing divide between North America’s preference for dry blended color and Europe’s broader use of compounded color. While most molders have a general understanding of the differences between the two approaches in terms of cost and appearance, there are also important performance considerations that can determine whether a material is suitable for a particular application. One of the most significant differences is the reduction in mechanical properties often associated with dry blended color, which is closely related to the pigment loading required to achieve a specific color shade. Next, Jake Kelly-Walley from Matrix Polymers presented “The Amide Advantage: A Story of Specialty, Advancement, and
52 ROTOWORLD® ISSUE 2 • 2026
Elevation for Rotomoulders.” He outlined several amide-based material solutions that Matrix provides to the rotomolding industry. PA6 offers excellent stiffness, typically four to five times greater than PE; however, it also absorbs moisture and has more modest impact strength. By comparison, PA11 and PA12 offer improved impact performance and lower moisture absorption, although they are not as stiff as PA6. Jake noted that PA6 can be moisture conditioned after molding to significantly improve its ductility and impact resistance. He also shared several industrial applications for these materials, including fuel tanks, hydraulic tanks, and compressed gas cylinders. Eric Maziers from TotalEnergies
OneTech Belgium wrapped up the day with a presentation titled “Sustainability Roads to the Success.” He introduced the development and launch of a new recycled polyethylene compound with a high level of recycled feedstock, designed to meet both sustainability and performance requirements for rotomolding applications in Europe. Across Europe, more countries are taking action by creating laws and penalties to encourage the use of recycled materials and polymers. However, scaling up production capacity for these recycled materials remains a significant challenge. TotalEnergies is committed to developing and offering sustainable material solutions for the European market. One example highlighted was rPE 4260, a compounded material containing 60% post-consumer recycled resin by weight. This material offers excellent ESCR and impact strength and is currently being trialed for fuel tank applications. Other potential applications include AdBlue tanks, chemical tanks, and technical parts.
Queen’s University Advanced Manufacturing Innovation Centre (AMIC)
Ronny Ervik discussed how European regulations and circular design principles are reshaping rotomolding.
Due to the civil unrest in the Belfast area, the AMIC tour was moved to the early morning of June 11th. Immediately after breakfast, conference delegates took a 15-minute bus ride north of the city to the newly constructed Queen’s University Advanced Manufacturing Innovation Centre (AMIC). AMIC serves as a “Factory of the Future,” connecting academic research with industry to accelerate innovation.
Supported by £100 million from the Belfast Region City Deal, AMIC helps businesses, especially SMEs, adopt Industry 4.0 technologies, de-risk product development, and test new processes in factory-like conditions. Its core strengths include smart design, digitalized manufacturing, sustainable polymers, composites, and nanotechnology. As an open access, industry led hub, AMIC brings together researchers, companies, and government partners to address challenges in aerospace, renewable energy, and materials handling. It also advances sustainability by promoting lowcarbon, green manufacturing practices. At AMIC the delegates had the opportunity to see the AMS Robomould technology, which was recently moved from the main Queen’s campus.
Day 2 Conference Proceedings
Following the AMIC tour, the conference resumed at the Grand Central Hotel. The first presentation was delivered by OREX ROTOMOULDING, a Polish manufacturer of rotational molding machines. The presentation, titled “Stability in the Process: Uninterruptible Power Supplies,” began with an overview of OREX ROTOMOULDING equipment and highlighted several advantages, including reduced gas consumption on machines with insulated arms. It concluded with a review of a two-stage solution for addressing the power fluctuations and grid instability that increasingly disrupts rotomolding operations, ranging from a low-cost control-voltage fix to a full online UPS architecture. Matt Bushman then presented a comparison of blow molding and rotational molding. He began by educating delegates on the
blow molding process, including videos that showed the production of a blow-molded part. He then introduced a process decision matrix that compared the two methods and highlighted which process was better suited for specific criteria. For example, tooling costs are generally lower for rotational molding, while high-volume production runs are typically better suited to blow molding. From this matrix, a practical summary can be developed to help select the optimal process for a given application. The presentation concluded with four examples of parts that had been produced using both processes, with the part designs remaining essentially the same in each case. These examples clearly demonstrated when rotational molding is the better option compared with blow molding, and vice versa. Matt finished by showing a video of a SMART machine demonstrating a highly automated rotational molding process used for furniture manufacturing. Just before lunch, Oliver Wandres gave a presentation titled “Full Automation Systems for Electrical and Conventional Rotational Moulding.” He began with an overview of his company, Maus, highlighting its broad capabilities and showing several examples of molds the company has manufactured, including a number of extremely large castings. Oliver also demonstrated the added value of accessories such as automated mold loading, insert loading, magnets, ejectors, drop boxes, Teflon coatings, and pneumatic clamping. He introduced a new non-Teflon coating called “Edelweiss,” which was developed specifically for mold flange
areas. Several examples of Maus electrically heated “Robomoulds” were also presented, showing how they are used in conjunction with AMS robotic molding machines. These systems are typically highly automated workcells capable of running 24 hours per day with limited operator involvement. After lunch, Dr. Paula Orcutt spoke about the leadership principle of “Picking Up a Broom” and how small, visible actions can have a significant impact on the manufacturing floor. Simple acts like these demonstrate genuine engagement and show employees that leaders care about both their people and their work environment. Paula encouraged company leaders to intentionally schedule time to walk the production floor and build relationships with associates. She emphasized the importance of making eye contact, smiling, waving, and greeting employees. Equally important is taking the time to listen to what shop floor associates are communicating. Their insights and concerns can provide valuable information that helps identify issues early and prevent problems before they occur. Next, Dr. Joe Butterfield presented “Reducing Product Development Lead Times Using Parametric Design.” Joe began by explaining the concept of a CAD kernel which acts as the functional “engine” of the design application – enabling the complex mathematical operations required for the creation of the CAD geometry through the platform interface. He then introduced parametric design principles which can be used to drive geometry creation using key product parameters, reducing the designer’s reliance on a conventional user interface.
www.rotoworldmag.com 53
He illustrated this concept with a range of storage tanks that shared similar geometry across a range of sizes and volumes and included standard features such as the inlet and outlet geometry. Once the tank proportions, key features, and design principles have been defined, parametric models for a full suite of tanks can be created in a matter of minutes. Normally, this type of development work for each individual tank would take several hours, if not days – depending on the skills of the designer. The same methodology can also be applied to tooling development where tank geometry can be used to drive parametric mold designs, including standard features such as flanges, clamps, etc. Tony Short then captured everyone’s attention with a spirited presentation titled “Investing in the Future of Rotational Molding Through Industrial Design”. He began by sharing a personal story about his father, a mold builder, who took great pride and ownership in the products made from the molds he created, including several Little Tikes toys. In recent years, Tony has been very active in
54 ROTOWORLD® ISSUE 2 • 2026
representing ARM at the Industrial Designers Society of America’s (IDSA) annual conference. He believes this involvement gives the rotational molding industry an important opportunity to become better known within the industrial design community and among universities. Inspiring the next generation of designers and helping them become excited about rotational molding must be a top priority for the industry. Tony also shared his experience working with the University of Notre Dame and described how rewarding it has been to raise awareness of the rotational molding process with young designers. Sergio Zilioli from Persico presented “A Half-Century of Innovation: From Handmade Patterns to Fully Automatic Machines.” Persico has had an impressive 50-year manufacturing journey, beginning when Pierino first started producing cast molds for the rotational molding industry. Since then, Persico’s growth has extended beyond rotational molding into the marine industry and the manufacture of highly automated equipment for the
automotive sector. The company became an industry leader in CNC-cut molds, providing precise, high-quality tooling to rotomolders around the world. In 2013, Persico USA was founded, allowing the company to expand its mold sales in North America. That same year, Persico introduced the SMART machine to the industry, along with electrically heated molds and new opportunities to fully automate both molding and finishing processes. In 2023, Persico acquired Precision Molds and moved its North American operations from Michigan to Precision’s Minnesota location. Today, Persico continues to expand globally with product offerings in marine, automotive, and rotational molding, while also entering new market sectors such as aerospace and medical. Johan Potargent of AMS Belgium BV followed with a presentation titled “Digital Twins, Simulation, and Data-Driven Rotomolding.” AMS is an international automation and manufacturing services company that has adapted six-axis robotic arms for rotational molding using electrically heated molds. Its “Robomould” technology is highly automated and can operate 24 hours per day with minimal supervision. Johan shared several examples of highly engineered and complex rotomolded applications, demonstrating the flexibility of this technology. More recently, AMS formed AMS Hydrogen Tech. BV to focus on producing hydrogen storage cylinders using rotational molding, a rapidly growing market sector in Europe. He also showed a range of Robomould applications before concluding with the many benefits of the technology, including no direct CO2 emissions, high levels of automation, improved quality,
faster manufacturing, and reduced maintenance requirements. Next, the dynamic duo of Dr. Nick Henwood and Dr. Gareth McDowell presented “Why Is It So Difficult to Control Your Cooling?”. Nick began by explaining how polyethylene chains fold to form lamellar crystals. Because not all chains fold, crystalline and amorphous regions coexist within the material. More crystalline materials tend to be stiffer, while materials with higher amorphous content tend to be tougher. During the cooling process, cooling rate can affect both crystallinity and shrinkage. Fast cooling typically produces lower crystallinity and less shrinkage, while slower cooling produces the opposite effect. Wall thickness is another important factor, since thicker walled parts naturally take longer to cool. Gareth then discussed the many variables that influence cooling, covering each stage of the molding cycle as well as material related factors. Several of these variables can contribute to shrinkage and warpage variation, including part design and the molder’s ability to consistently achieve a uniform wall thickness. Controlling the point at which the part releases from the mold can also be challenging, since the mold surface changes over repeated production cycles and operators must determine when and where to apply mold release. These factors help explain why controlling part cooling can be so difficult. Gareth concluded by introducing a new simulation software called “Simoulding,” which can predict wall thickness distribution. The final presentation, “Digitalisation of Rotomolding,” was delivered by Mark Kearns. Mark explained how digitalization
can enable the use of big data and AI-driven predictive analytics to improve process control, reduce cycle times, and enhance product quality. He demonstrated several digital rotomolding and virtual reality case studies, including one used to optimize the design of a finishing workcell. This type of simulation can help improve labor efficiency, product flow, and space utilization; while also giving stakeholders a clearer understanding of how the work area will look and function.
the events unfolding around us helped unite the group in Belfast in a meaningful way. The social gatherings were a great deal of fun, especially the evening of June 10th, when 493K hosted the group with music, food, and beverages following the day’s proceedings. The evening concluded with quizmaster Ronny Ervik, wearing his red 493K lab coat, hosting a Kahoot quiz created by Kerri McKee. It provided several hours of entertainment before the mystery winner and runner-
Every Cloud has a Silver Lining
up were revealed. Thank you to Gareth McDowell and Kerri McKee of 493K for hosting and planning such a memorable evening and for developing a self-guided Belfast pub-crawl experience for those who wanted to enjoy more of the city’s culture. Also, Orla Nugent helped facilitate city tours for the spouses and partners who attended. Together, these efforts created a rich cultural experience for everyone who participated. Thank you to all those who gave so generously of their time and resources to make this event such a great success! R
The older I get, the more I appreciate the ARM community and the wonderful people who are part of it. ARM is fortunate to have outstanding suppliers who are willing to sponsor events like this, and their support makes a tremendous difference to the overall conference experience. A sincere thank you goes to our sponsors, including RotoLoad, Matrix Polymers, 493K, and others who helped make the event possible. Although we were unable to use our special venue at Queen’s University, I genuinely believe
www.rotoworldmag.com 55
PRACTICAL ROTO TIPS
R. DRU LAWS Brigham Young University – Idaho
MANUFACTURING: More Than Making Parts Manufacturing has been the focus of my professional life for nearly three decades. Throughout my career, I have had the opportunity to experience manufacturing from many different perspectives: first as a mechanical engineer designing products and solving technical challenges, then as a manufacturing engineer improving processes and systems, later as a manager and executive responsible for people, strategy, and business performance. Today, I have the privilege of teaching Manufacturing Engineering Technology students and helping prepare the next generation of manufacturing professionals. Looking back across these different roles, one lesson has become increasingly clear:
Manufacturing is much more than making parts.
Making quality products is the visible result of manufacturing, but the discipline itself is far broader. Manufacturing is where engineering meets reality. It is where materials, processes, equipment, people, and business decisions come together to transform an idea into a product that can be produced consistently, efficiently, and profitably. For many people outside of manufacturing, the process can appear simple. A customer has a need, an engineer designs a product, and a factory produces it. But anyone who has spent time on a manufacturing floor understands that the reality is
56 ROTOWORLD® ISSUE 2 • 2026
far more complex. Between the initial design and the finished product exists an entire world of decisions, challenges, improvements, and problem solving. That is manufacturing.
MANUFACTURING IS A SYSTEM
One of the most important lessons I have learned is that manufacturing is not defined by a machine or a process. It is a system. The equipment matters. The materials matter. The tooling matters. The process parameters matter. But equally important are the people who understand how those pieces interact.
A modern manufacturing operation depends on the integration of many disciplines: • Product design • Materials selection • Process development
PRACTICAL ROTO TIPS
• Tooling • Quality systems • Maintenance • Automation • Supply chain management • Continuous improvement A company can have excellent equipment and still struggle if the process is not understood. It can have talented engineers and still struggle if knowledge is not transferred to the people running the equipment every day. Successful manufacturing requires alignment between all parts of the system. This is especially true in rotational molding. At first glance, rotomolding may appear straightforward: fill a mold with polymer powder, heat it while rotating, cool it, and remove the finished part. However, experienced rotomolders know that producing consistent, high-quality parts requires a deep understanding of the interaction between resin characteristics, powder properties, mold design, heat transfer, oven conditions, rotation, cooling, and inspection methods. The process may look simple. The manufacturing discipline behind it is not.
MANUFACTURING IS ABOUT PROBLEM SOLVING
Throughout my career, I have noticed a common trait among the best manufacturing professionals: they are problem solvers. They do not simply ask, “How do we make this part?”
They ask:
• Why did this problem occur? • How do we know what caused it? • What data supports that conclusion? • How can we prevent it from happening again? • How can we make the process better for the next person? This mindset separates manufacturing from simply producing. Production is focused on successfully executing today’s process. Manufacturing is focused on understanding and improving the process, so tomorrow’s production is better. Both are essential. A company cannot succeed without producing products. However, companies that thrive over the long term are those that continually improve the way products are made.
MANUFACTURING REQUIRES GOOD PARTS AND GOOD DATA
One lesson I consistently shared with production teams throughout my career was that every person in manufacturing has two important responsibilities: 1) Make good parts 2) Make good data. The first responsibility is obvious. Customers expect quality products that meet specifications, perform as intended, and are delivered on time. The second responsibility is sometimes overlooked. Manufacturing decisions are only as good as the information behind them. A company can have excellent employees, great equipment, and talented engineers, but if the data coming from the manufacturing floor is inaccurate, incomplete, or inconsistent, the organization will struggle to improve.
Good data allows us to answer important questions:
• Did the process actually improve? • Did a change reduce scrap or simply move the problem somewhere else? • Is a quality issue random, or is a trend developing? • Are we making decisions based on facts or assumptions? In manufacturing, data is the connection between what we believe is happening and what is actually happening. This is especially important in processes such as rotational molding, where many variables influence the final product. Resin characteristics, mold conditions, oven profiles, cooling rates, and process parameters all affect part quality. Without accurate process information, troubleshooting becomes guesswork. A good manufacturing culture values both the parts being produced and the information being captured during production. The operator who records accurate process data is contributing just as much to future improvement as the engineer analyzing that data. Making good parts keeps the customer satisfied today. Making good data allows the company to make better parts tomorrow.
THE ROLE OF ENGINEERS IN MANUFACTURING
One misconception I have encountered throughout my career is that manufacturing belongs to a specific engineering discipline.
www.rotoworldmag.com 57
PRACTICAL ROTO TIPS
In larger companies, engineering roles are often divided into specialties. Mechanical engineers may focus on product design. Manufacturing engineers may focus on processes. Quality engineers may focus on variation and compliance. Industrial engineers may focus on efficiency and workflow. However, many of the companies that make up the manufacturing landscape, including many small and medium-sized rotomolding companies, do not have the luxury of separate departments for every specialty. An engineer is often simply an engineer. And that is okay. In fact, it can be a tremendous advantage. In smaller organizations, engineers often have the opportunity to see the entire manufacturing system. They may work on product design one day, troubleshoot a process issue the next, help improve quality the following day, and work directly with customers after that. This broad exposure develops something extremely valuable: manufacturing intuition. Many mechanical engineers eventually find themselves working in manufacturing because manufacturing is where engineering decisions become reality. A design is only successful if it can be produced consistently, economically, and at the required level of quality. The best engineers are not defined by their job title. They are defined by their ability to understand problems, work with people, and improve processes.
PREPARING THE NEXT GENERATION
After spending decades working in industry, I now have the opportunity to teach Manufacturing Engineering Technology students. This transition from industry to education has given me a unique perspective. Early in my teaching career, I thought my responsibility was primarily to transfer technical knowledge: teach students about materials, machines, processes, and manufacturing methods. Those things are important, but I have learned that education is about much more than transferring information. Technology will continue to change. Machines will become more automated. Software will continue to evolve. New materials and processes will emerge. The most valuable skill we can develop in future manufacturing professionals is the ability to learn, adapt, and solve problems. Students need hands-on experience. They need to understand materials and processes. They need to
58 ROTOWORLD® ISSUE 2 • 2026
operate equipment and experience the realities of manufacturing. But they also need to learn how to think like manufacturing professionals. They need to ask why. Why did the process change? Why did quality improve? Why did it fail? Why does one solution work better than another? Those questions are at the heart of manufacturing.
THE FUTURE OF MANUFACTURING
Manufacturing has always evolved. The tools, technologies, and processes used today are dramatically different from those used decades ago. However, one thing has remained constant: successful manufacturing depends on people. Automation, data analytics, and advanced manufacturing technologies will continue to transform the industry. But technology alone does not create successful manufacturing operations. People do. The future belongs to companies that develop employees who understand both technology and process. It belongs to organizations that encourage curiosity, continuous improvement, and lifelong learning. The rotomolding industry has always been built on innovation and practical problem solving. From advances in materials and equipment to improvements in process control and automation, the industry continues to evolve. The next generation entering manufacturing will not just be responsible for making parts. They will be responsible for making manufacturing better. That is the true purpose of manufacturing: not simply creating products, but continually improving the systems, processes, and people that make those products possible. R
WOMEN IN ROTO
CONCHITA MIRANDA Miraplastek – Mexico
FLOR PONCE
Director of Human Resources at Centro Incorporated In this issue, we are back in North America to talk with a key collaborator in one of the most important rotational molding companies worldwide. Flor Ponce is Director of Human Resources at Centro Incorporated, and lives in Cedar Rapids, Iowa with her husband Juan. They have four children — Juan Jr., Jossy, Ivana, and Daniel — and are now enjoying life as empty nesters. They love traveling, gardening, and photographing sunrises and sunsets. Hi, Flor, please tell us your company and briefly describe your role within the organization. Centro is a custom rotational molding company based in North Liberty, Iowa, with operations across five U.S. states, Brazil, and Northern Ireland. I oversee HR both at the strategic and operational level. I see my role as a culture advocate — protecting what makes our company special while helping it evolve and serving as the bridge that connects leadership and our Associates. How did you first become involved with the rotational molding industry, coming from an HR perspective? My path into rotational molding was not something I planned — it was part of my life journey. I’m
www.rotoworldmag.com 59
WOMEN IN ROTO
originally from Honduras, and that journey has shaped how I connect with people. When I came to the United States, language barriers limited my initial career options, and a role as a manufacturing operator became my entry point into the workforce. I had a formal education in Business Administration and Finance, and over time — through hard work and saying yes to opportunities — I moved into Human Resources. Starting on the production floor gave me a deep understanding of how much impact people leadership can have in operational environments. Joining Centro in 2019 introduced me to the world of rotational molding and a completely new side of manufacturing. At first, I had a lot to learn about the process, the technical side, and the workforce dynamics. Today, it’s incredibly rewarding to work in an industry that continues to create opportunities for others, just as many people once created opportunities for me. From your point of view in Human Resources, what makes rotational molding companies different from other manufacturing environments? From my perspective, rotational molding feels very personal. It’s not just about machines or production lines — it’s about people working closely together to build custom parts. The work requires technical knowledge, but also strong teamwork between production, engineering, and support teams. Many companies in rotational molding also began as family
60 ROTOWORLD® ISSUE 2 • 2026
businesses, so culture, loyalty, and relationships tend to run deep. At Centro, I experience every day the strong sense of community that exists in the rotomolding industry.
THAT FAMILYBUSINESS SPIRIT IS STILL VERY PRESENT. Your company evolved from a family-owned business into part of a larger conglomerate. How did that transition impact the company culture and people management? Yes, Centro started as a familyowned business, and even though today we are part of Tank Holding, that family-business spirit is still very present. You can see it in the way our leaders support their teams, the pride people have in the
Centro brand, and the strong sense of belonging across the organization. Our CEO, Brian Olesen, and the executive team have done a great job reinforcing those values as the company continues to grow. During this transition, communication has been key, helping our Associates understand what is changing, what is staying the same, and how they continue to be part of the company’s future. What are the biggest challenges when recruiting and retaining talent for rotational molding operations today? One of the biggest challenges today is finding skilled talent willing to work in a manufacturing environment, especially in technical and production roles. Competition for labor is strong, and expectations have evolved. The new generations are looking not only for growth and stability, but also for flexibility. Retention today is less about pay alone and more about the overall employee experience. What skills or qualities do you look for when hiring people for rotomoldingrelated roles, especially on the production floor? When I joined Centro, one element of the culture I immediately loved was the “Hire for Attitude, Train for Skills” philosophy. Instead of expecting every candidate to arrive with all the technical skills, we invest in training and development. Attitude, accountability, and work ethic are much harder to teach if they are not already there. For production roles, we look
WOMEN IN ROTO
for people who understand the importance of working safely, follow established processes, and show up to work every day on time. This approach not only helps us fill roles, but it also builds loyalty and long-term growth for our Associates. From your experience, have you observed differences in how men and women experience work opportunities or challenges in manufacturing and rotomolding environments? Manufacturing has traditionally been a male-dominated field, so women sometimes notice differences in representation. My perspective has always been to focus on preparation, performance, and confidence. In my experience, respect in manufacturing comes from building trust over time. Companies should always hire and promote based on merit. When women bring strong skills, commitment, and leadership, opportunities naturally follow. Progress comes from both individual drive and workplaces that support growth and fairness. How can HR departments actively contribute to creating more inclusive, safe, and supportive workplaces in industrial settings? HR plays an important role in shaping the workplace environment. Creating an inclusive workplace means making sure everyone feels respected, heard, and treated fairly — but it’s not just about policies on paper. It’s about how those values are lived every day on the
production floor. That starts with open communication, leadership training, clear expectations, and accountability for how people treat one another. What has been one of your proudest professional achievements in HR within this industry? One of my proudest professional achievements isn’t a program or a metric — it is seeing people grow. For me, success in HR is about recognizing potential in others, investing time in their development, and helping create opportunities they may not have imagined for themselves. I take a lot of pride in having mentored some of my team members. Watching someone gain confidence, develop new skills, and build a career reminds me why this work matters. I never forget how important opportunity and support were in my own journey, so being able to pay that forward is incredibly meaningful to me. What advice would you give to companies and to women considering careers in HR or manufacturing to help strengthen the future workforce of the rotational molding industry? For companies, my advice is simple: invest in people development, leadership training, and culture. Those investments are just as important as investing in technology and equipment. When companies promote from within, they not only strengthen loyalty and retention, they also develop leaders who truly understand the organization’s values and vision.
For women considering careers in manufacturing or HR in this field: don’t be intimidated. There is space for your voice, your leadership, and your perspective. Be curious, stay confident, and seek mentors. This industry needs diverse talent to continue growing. I truly believe women don’t need to wait for the industry to change for them — we can step in, learn the business, take ownership of our careers, and help shape its future. What stands out most in Flor’s story is not only her professional trajectory, but the character behind it. Arriving in a new country, facing language barriers, and choosing to begin on the production floor requires a level of determination that cannot be taught. Through consistent effort, an openness to opportunity, and a clear sense of purpose, she has built a path that is both solid and well earned. Her journey reflects the strength of someone who grows without losing sight of her values—and that is precisely what makes her voice in this industry so credible and relevant. For next issue, we will stay in North America to interview a very interesting woman. See you soon, dear Rotoworld readers! R
www.rotoworldmag.com 61
ARM REPORT
The mission of the Association of Rotational Molders is to promote, educate, and inspire the rotomolding industry. For more information, visit ARM’s website at www.rotomolding.org or contact the Association at 630.942.6589 or info@rotomolding.org.
PRESIDENT’S MESSAGE
Our 50th Anniversary Year is Off and Running Dear friends, In my first message of the year, I told you we would celebrate our 50th anniversary all year long. I am happy to report that we are doing exactly that. Our Executive Forum in Belfast was a rewarding experience. While circumstances required us to adjust our plans and hold sessions at our hotel rather than on the Queen’s University campus, the spirit of the event was everything I hoped it would be. Belfast has been part of our industry’s story for decades. So much of the research and technical knowledge that helped rotomolding grow into what it is today came from that city and its university. Many of the experts shaping our industry were educated and developed there. We were also able to tour Queen’s University’s Advanced Manufacturing Innovation Centre, a brand-new facility dedicated to manufacturing and engineering. Walking through that building, you could feel the ambition. It was built to reinvigorate Northern Ireland’s industrial potential and to prepare the region’s manufacturing sector for the technology and skills challenges ahead. That is exactly the kind of forward thinking our industry needs, and it was inspiring to see it up close. For those of you who joined us, I think you felt it too. For all our members, our new website continues to gain momentum. Members are exploring the improved tools and resources, and I encourage all of you to do the same. Whether you are looking for technical content, online training, or ways to promote your company through our directories, the website is designed to work for you. Log in regularly and make the most of what your membership offers. You might be surprised by what you find. And then, dear friends, comes New Orleans. Rotoplas 2026 will take place this November and will serve as the centerpiece of our 50th Anniversary celebration. Planning is well underway, and I can tell you this will be a special one. We are bringing together rotomolders from across the world for education, networking, and the kind of celebration this milestone deserves. If you were with us for the 40th in New Orleans ten years ago, you know what this city does for our Roto Family. If you were not there, this is your year. Register early. And if your company is interested in exhibiting, secure your booth space soon. You will want to be part of this. Learn more at www.rotoplas.org Fifty years ago, a small group of competitors decided to become partners and build something together. Every year since then, we have proved them right. Let’s keep proving them right. ¡Hasta la vista! Conchita Miranda Directora General, Miraplastek President, Association of Rotational Molders
62 ROTOWORLD® ISSUE 2 • 2026
ARM REPORT
Rotoplas: The World of Rotomolding Under One Roof
Registration is open for Rotoplas 2026, the largest gathering in the world for rotomolders and their suppliers, November 17 to 19 in New Orleans. This year we’re also celebrating ARM’s 50th anniversary with a meeting that will include a Reception at the WWII Museum. This is where you find the machine that speeds up your line, the material that fixes your scrap problem, and the people who have already solved what you are working on right now. More than 60 exhibitors are already signed up. The exhibit hall floor, the highlight of Rotoplas, is open Wednesday and Thursday, November 18 and 19. You will see the newest machinery, materials, and tooling in the industry in one place, alongside the people who build them. The conversations in the aisles and over dinner tend to pay for the trip on their own. That is often what most attendees say they value most.
A program built for ROI
The technical program runs Tuesday through Thursday, and the first approved sessions are detailed below. This is only the start of the program. By the
time you read this, more sessions will have been announced. See the lineup at www.rotoplas.org.
Seminars
• Rotomolding 101, Dru Laws. The whole process in one day, from materials to design. Newcomers and longtime rotomolders all tell us they find value in this session. • Advanced Rotomolding, Dr. Nick Henwood. Tighten cure, thickness, cooling, and oven efficiency to attack your top causes of scrap. • Design Seminar, Michael Paloian. Learn the industry’s accepted design guidelines from 30 years of real rotomolded case studies.
Annual Meeting Sessions
• Keynote: Aron Ralston. The survivor behind 127 Hours on turning your hardest “boulders,” personal and professional, into momentum. • Keynote: Economic and Policy Update, Alex Chausovsky. A clear-eyed 2026 outlook on tariffs, rates, and demand, with tactical advice for planning your business. • AI on the Production Floor, Marthijn Koorn, Pentas. Factory-proven, practical ways to start putting AI to
www.rotoworldmag.com 63
ARM REPORT
work in your operation. • Anatomy of Losses, Przemysław Orlik, OREX Rotomoulding. Real-test strategies to cut energy and material cost on carousel and shuttle machines. • Consistent Venting, Kelly Cline, RotoMesh by ATHENA. How steady airflow drives part quality and lowers scrap, backed by new BYU-I data. • Graphene-Enhanced Materials, Daniel Tsai, Asbury Advanced Materials. How graphene additives lift part properties and shorten heating and cooling cycles. • The Hidden Cause of Yellowing in White Parts, Dave Sullivan and Kyla Egerdeen, Borouge International. Why white parts yellow, and how to stop the scrap it causes. • Thermally Reversible XLPE, Dr. MiaoMiao Xiao, Ingenia Polymers. A crosslinked PE that keeps XLPE’s toughness but can be remelted and recycled. • Tight Corner Lids, Jason Rycroft, Borouge International. How melt flow and grind quality decide whether tight features fill cleanly or fail. • What’s New from Asbury Advanced Materials. New compounding, coatings, and graphene technology aimed at cutting resin use and operating cost. • Why Some Products Look Premium, Jim Crawshaw, PSI Brand. A practical playbook for branding and identification that survives decades outdoors. • What’s New from STP Rotomachinery, James Hould, STP Rotomachinery. A technical review of a carousel rotomolding machine that has undergone a comprehensive re-evaluation prior to manufacturing.
ticketed separately and space is limited, so reserve your spot when you register.
Honey Island Swamp Tour
Mon, Nov 16 · 1:30–5:30 PM · $115 Glide through gator territory on a flat-bottomed boat with Cajun Encounters’ local expert captains, exploring one of America’s most unique ecosystems.
Garden District Walking Tour
Tues, Nov 17 · 1:30–4:30 PM Walk New Orleans’ oldest neighborhood with an area expert. Landmark architecture from film and television, the Buckner Mansion, and historic Lafayette Cemetery #1.
Attendee Types and Meeting Details
Rotoplas is organized so you can attend in the way that makes sense for your business. Register for the full event or the exhibit floor only. Most of the meeting is held at the New Orleans Convention Center, with the Welcome Reception at the National WWII Museum and the 50th anniversary gala and awards dinner at Mardi Gras World. Register early and save. Early bird pricing ends October 16, and our host hotel blocks fill quickly, so book your room when you register.
Make the most of New Orleans
Rotoplas is built around the show floor and the program, but the city is part of the draw. These optional tours and activities give you and your guests a way to experience New Orleans together. Each is
64 ROTOWORLD® ISSUE 2 • 2026
Jewelry Class with Emma Fick
Wed, Nov 18 · 9:00–11:00 AM Spend the morning making jewelry with local New Orleans artist Emma Fick. She supplies the pieces, the inspiration, and the how-to. You will leave with a oneof-a-kind, ready-to-wear pair of earrings.
WWII Museum: Beyond the Galleries
Fri, Nov 20 · 10:00 AM–1:00 PM A private, guided experience at the National WWII Museum. Handle genuine artifacts the public never sees and explore the Campaigns of Courage pavilion. Register now at www.rotoplas.org. R
ARM REPORT
ARM Belfast Recap: A Week to Remember Eighty-five members of the rotomolding community from ten countries met in Belfast in June for a meeting we will never forget. ARM organized this Executive Forum and Tour as part of our 50th anniversary and to recognize the rotational molding industry’s long history with Queen’s University Belfast. Our group left the Grand Central Hotel Belfast on the morning of June 9 for the first factory tour of the day, Kingspan Water and Energy in Craigavon. As one of Europe’s most prominent rotomolders, Kingspan impressed us with its scale and level of organization, and the presentation on the company’s wider businesses and core values was fascinating. After lunch we visited Collins Aerospace in Kilkeel. For anyone interested in Lean Manufacturing, the visit was inspirational, with lessons that could carry over to anyone setting up a roto plant on the same principles. That evening, June 9, riots broke out across Belfast after a stabbing the night before. Masked men torched a bus, burned cars, threw rocks and bricks at police, and set fire to homes they believed housed immigrants. Businesses closed, trains stopped running, and schools let students out early. Our group met for dinner at a restaurant across the street from Belfast City Hall. The next morning, we began with a fresh start, touring Clarehill, a great example of a multi-generational, familyrun business that has been pivotal in the development of the industry on the island of Ireland. Some of their custom jobs sit at the cutting edge of roto technology. The threat of continued unrest appearing on social media that morning forced another change of plans. Road closures and the closing of the university made our scheduled sessions at Queen’s impossible at the last
minute. Grand Central Belfast Hotel hosted our meeting instead and their chef prepared lunch on short notice. We kicked off with “How Queen’s Became Rotomolding’s Research Home,” a panel with Mark Kearns, Paul Nugent, and Alvin Spence. Three people with deep ties to Queen’s and the industry traced the arc of innovation through the university’s different eras, from Roy Crawford’s early work through today’s Advanced Manufacturing Innovation Centre. That evening the disorder returned on a smaller scale, with police deploying water cannons in Newtownabbey. Bus and train closures continued. Our planned pizza and a pint party on the Belfast Barge became a hotel event, with ARM staff searching the quiet downtown streets for restaurants that hadn’t closed early and could prepare enough pizzas for our group. We all enjoyed a pub quiz led by Ronny Ervik that featured Northern Ireland and rotational molding trivia. On June 11 we visited Queen’s University’s Advanced Manufacturing Innovation Centre, an exciting glimpse into the future of industry by previewing their brand-new state-of-the-art building. It was good to see rotomolding playing a pivotal role in AMIC’s development. That afternoon our education sessions continued at the hotel. For lunch and dinner, we were served the menu from another group that had canceled their Thursday event. Much of this was not the meeting we planned. But our hosts at every plant, our 85 attendees who rolled with every change, and our sponsors 493K, Matrix Polymers, and RotoLoad made sure the Belfast Executive Forum remained valuable for all. This was one we’ll be talking about for another 50 years. R
www.rotoworldmag.com 65
SPREADSHEETS ARE OUT. AI IS RUNNING THE PLANT. BETTER. AI is Moving Manufacturing from Reactive to Real-Time and Driving Higher Plant Output JONATHAN SMALLEY CEO, ROTOEDGE PRO
The rotational molding industry has long been defined by durability, craftsmanship, and process knowledge. But when it comes to plant operations, many facilities are still running on systems that haven’t kept pace with today’s production demands. Paper-based scheduling, whiteboards, and production reports that arrive days after the fact remain common. While these methods once worked, they are increasingly out of step with a manufacturing environment that demands speed, precision, and adaptability. As production cycles tighten and margins face increasing
pressure, inefficiencies become more costly. A growing number of rotomolders are now turning to artificial intelligence (AI) to bridge that gap, and are shifting from reactive management to real-time operational control.
The Limits of Traditional Plant Management
In many plants, production decisions are still based on historical data, including reports that may be two or three days old by the time they are reviewed. By then, the opportunity to correct inefficiencies, reduce scrap, or optimize scheduling has already passed. This delay
REAL-TIME PLANT INTELLIGENCE
66 ROTOWORLD® ISSUE 2 • 2026
creates a ripple effect: • Scrap issues go unaddressed in real time • Machine utilization is less than optimal • Labor is assigned based on assumption rather than need • Customer delivery timelines are harder to manage
A Shift Toward Real-Time Insight
AI is enabling a new operational model—one where data is not just collected, but actively interpreted and delivered in real time. The result is a move away from static planning toward adaptive, datadriven decision-making.
In AI-enabled plants, managers and operators can: • Monitor machine performance and output continuously • Track scrap and identify root causes as they occur • Adjust schedules dynamically based on current conditions • Access up-to-the-minute inventory and order status • Run “what if” scenarios to evaluate process changes
Bringing AI to the Plant Floor
One example of this shift is the emergence of RotoEdge Pro, the AI and real-time software platform designed specifically for rotational molding and manufacturing operations. The RotoEdge Pro system combines top-down visibility with bottom-up usability. This allows both plant managers and floor workers to interact directly with the same intelligence layer that’s as easy to use as an iPhone®. Operators receive immediate feedback and guidance as they work, while managers gain a comprehensive, real-time view of plant performance, including scrap rates, machine efficiency, margins, and labor utilization. Rather than simply reporting problems, the system can recommend actions, such as adjusting staffing, modifying schedules, and changing processes to remedy problems to address inefficient methods.
Instead of reviewing yesterday’s data, plant leadership can receive live updates on: • Production output and trends • Scrap levels and margin impact • Work-in-progress (WIP) • Inventory status • Customer order progress This RotoEdge Pro AI-driven briefing system includes actionable insights, such as recommended labor reassignments or alerts when performance deviates from targets. This approach allows managers to intervene immediately, and reduces downtime, minimizes scrap, and improves throughput: from WIP to Ship.
A Digital Assistant for Manufacturing
As AI becomes more integrated into plant operations, it is increasingly functioning as a kind of digital assistant. For rotational molders, this means more efficient use of ovens, better coordination across shifts, and improved consistency in output.
By analyzing both historical and real-time data, AI systems can: • Identify patterns that may not be visible through traditional reporting • Highlight emerging issues before they escalate • Optimize machine loading and scheduling • Support workforce planning and training decisions
The Labor Gap Doesn’t Have to Be a Knowledge Gap
Manufacturers are struggling to find, hire, and keep experienced workers. New employees often arrive with little manufacturing knowledge, but need to become productive fast. Supervisors still have to train workers, maintain quality, hit production targets, and keep orders moving. There’s little room for long training cycles, mistakes, or scrap.
AI Helps Workers Learn on the Job
RotoEdge Pro AI turns production issues into real-time
From Reports to Real-Time Briefings – Audio Updates in Your Pocket A notable development in AI-driven manufacturing is the replacement of static reports with continuous briefing systems.
Operators and supervisors use real-time updates and AI recommendations to keep production on track.
www.rotoworldmag.com 67
Fast Implementation, Immediate ROI
recommendations and howto guidance. It tracks worker productivity and helps supervisors instantly adjust scheduling and staffing as production needs change. AI-based guidance gives new and less-experienced workers the how-to support they need on the job. If production falls behind shift or daily KPIs, supervisors can reassign workers and deliver AI-based training recommendations through the system. The result is
coordination on the plant floor. In several cases, companies expect to take on additional business as a direct result of these operational improvements—leveraging existing resources more effectively rather than expanding labor. “The thing that is really interesting us is the ability to be able to do predictive dollar output on the machines by how we load them. Our operations are now driven by the production accounting – and we are
01 PAPER LAG
02 DIGITAL VISIBILITY
03 AI GUIDANCE
(now) becoming as efficient as we can be.” —Simon Gough, CEO, Gough Plastics “RotoEdge Pro gave our production team the ability to manage the plant in real-time – which increased output and efficiency without having to hire new staff.” —Scott Humpries, IRM “We expect to be able to add business with our existing worker level, and as a result of our increased revenue.” —Elizabeth Cunningham, Rescraft
The Future of Manufacturing Is Now
faster learning, higher productivity, fewer mistakes, and less scrap.
Early Results from the Field
Manufacturers already implementing the RotoEdge Pro-AI-based system are reporting measurable gains. Some have noted improvements in machine efficiency driven by better load planning and predictive output modeling. Others have increased overall production without adding headcount, simply by improving visibility and
68 ROTOWORLD® ISSUE 2 • 2026
Unlike traditional enterprise systems, the RotoEdge Pro-AIbased solution is designed for rapid deployment. This ease of adoption removes one of the biggest barriers to digital transformation. • Installation takes days • The interface is intuitive—similar to using a smartphone • Measurable results are often seen within weeks
The manufacturing landscape is evolving quickly. To stay competitive, plants must operate at the speed of real-time data. Rotomolders must optimize scheduling, control costs, be able to automatically identify issues and scrap, and improve processes and delivery performance. AI platforms such as RotoEdge Pro deliver fast, proven results that increase productivity and revenue:
WORKER CHECKS AI GUIDANCE ON ROTOEDGE PRO TOUCH SCREEN
• Rapid deployment timeline: in days. • User interfaces designed for ease of use – as easy as an iPhone®. • Immediate tracking of WIP, inventory, and plant and shift efficiency. • Recommended solutions for production challenges.
The Road Ahead
The role of AI in rotational molding is still evolving, but the direction is clear. As market demands increase and production environments become more complex, the ability to make fast, informed decisions will be critical. AI offers a path forward— enabling plants to operate with greater agility, efficiency, and precision. For an industry built on process control and consistency, the shift to real-time, AI-driven insight represents the next major step in its evolution.
Manufacturing / Rotational Molding Solutions Are Available Now
AI-powered manufacturing solutions are no longer experimental. They are proven, available, and delivering results today.
USING ROTOEDGE IN THE PLANT
RotoEdge Pro delivers usable AI that is tested and works today in the plant. RotoEdge Pro-AI delivers top-down and bottom-up Usable AI that provides managers with an instant summary of all machines, worker productivity, revenue, customer order and inventory and scrap status. And gives workers simple, explanatory terms to your workforce to help them work efficiently and be more productive.
RotoEdge Pro:
• Provides integrated labor and machine optimization • Delivers continuous performance insights and recommendations • Digitally and automatically schedules molds, arms, teams
and machines. • Provides triggered analysis, historical data, and immediate recommended solutions • Automatically alerts plant managers and workers about scrap levels and production situations • Increases overall plant productivity RotoEdge Pro-AI is available now to all current customers. Rotational molding and plastics manufacturers that are interested in a product demonstration, on-site testing or benefits assessment can contact RotoEdge Pro at https://rotoedgepro.com/ or Phone at +1-360-600-9778. R
www.rotoworldmag.com 69
ARMO NEWS
ARMA | ARM-CE | ARMSA | BPF | IT-RO | NORDIC ARM | StAR
Tim Leed Named 2026 Icon of Rotomoulding ARMA was proud to recognise Tim Leed as the 2026 Icon of Rotomoulding at the Rotomould26 Conference Dinner, honouring his long-standing contribution to the rotational moulding industry across Australasia. A highly respected industry leader, Tim has contributed to the sector over many decades through both business leadership and active industry service. As Director of Melbourne Rotomould, a wellestablished Victorian manufacturer, Tim has helped build and support a business known for its technical capability, quality manufacturing, and ongoing commitment to the industry. Tim’s contribution extends far beyond his own organisation. He has been a committed supporter of the Association of Rotational Moulders Australasia (ARMA) for many years, serving in multiple leadership roles including Board Member, Treasurer, Vice President, President, and Past President. This breadth of service reflects not only his longevity in the industry, but his willingness to contribute at every level of governance and leadership. Throughout his involvement with ARMA, Tim has consistently demonstrated a practical, hands-on approach to supporting the sector. He has contributed to subcommittees, supported key ARMA initiatives, opened his manufacturing facility for tours and industry visits, encouraged workforce development by sending staff to conferences and events, regularly attended and contributed to Rototours, and shared his knowledge through conference presentations and practical masterclasses. Tim is widely regarded as a collaborative and dependable contributor who leads by example. His willingness to share knowledge, support peers, and invest in industry capability has had a meaningful and lasting impact on the rotational moulding community. Speaking at the award presentation, Tim’s business partner at Melbourne Rotomould, Steve Kyval, reflected on the qualities that make Tim such a valued member of the industry. “What stands out most to me is the way Tim connects with our industry. If there is an opportunity out of our reach, he is the first to pick up the phone, and when people call in to talk rotomoulding, he totally lights up,” Steve said.
70 ROTOWORLD® ISSUE 2 • 2026
TIM LEED
Melbourne Rotomould
“Tim knows that our industry moves forward when we help each other. Problems don’t exist — we’ve only got solutions. And to me, these are the qualities that make an ARMA Icon. Congratulations Tim, this is a well-deserved honour, and may it lead to many more rotomoulding conversations ahead.” Tim’s combination of business leadership, sustained service to ARMA, and genuine commitment to advancing the industry makes him a fitting recipient of the 2026 Icon of Rotomoulding award. R
ARMO NEWS
Student Design Awards Showcase the Next Generation of Rotomoulding Talent ARMA’s Student Design Awards once again celebrated the next generation of talent coming into rotational moulding, highlighting the creativity, technical thinking, and rotational moulding to life innovation emerging from beyond the classroom. universities across Australia ARMA extends a special and New Zealand. thank you to Melbourne On display at the Rotomould and Devan Plastics Rotomould26 conference, for hosting factory tours, this year’s program attracted giving students the opportunity 22 nominations from four to see rotational moulding universities: the University in practice and better of Waikato and Otago understand the practical Polytechnic in New Zealand, considerations behind and Swinburne University successful product design. of Technology and Monash A big thank you also goes to University in Australia. the lecturers who supported The awards provided and facilitated the program, students with an opportunity encouraging students to to explore the possibilities engage with rotational ARIANA TEJADA MUNIVE of rotational moulding and moulding and consider its with her winning entry, Seatly apply their design skills to potential across a wide range products that considered of applications. both form and function. Entries demonstrated a A panel of expert judges carefully assessed strong understanding of design intent, usability, each entry, considering criteria such as design and the manufacturing process, reflecting the value innovation, manufacturability, functionality, and how of connecting emerging designers with real-world effectively students demonstrated an understanding industry knowledge. of rotational moulding principles. With a high-quality As part of the program, students were supported and diverse field of submissions, selecting the by lecturers and industry partners who helped bring winners was no easy task. Continued on page 72
1ST PRIZE: SEATLY SHOWER CHAIR Ariana Tejada & Ava Christophers Swinburne University of Technology
2ND PRIZE: SHORE Sebastian Leim Otago Polytechnic
3RD PRIZE: HOME SAFE Jack Callear Otago Polytechnic
www.rotoworldmag.com 71
ARMO NEWS
Continued from page 71 The winners were announced during Rotomould26, recognising outstanding student achievement and celebrating the ideas, effort, and enthusiasm shown throughout the program. This year’s winners were: • 1st Prize: “Seatly Shower Chair” by Ariana Tejada Munive & Ava Christophers from Swinburne University of Technology.
• 2nd Prize: “Shore” by Sebastian Leim from Otago Polytechnic. • 3rd Prize: “Home Safe” by Jack Callear from Otago Polytechnic. Congratulations to the winners, and thank you to all students, lecturers, judges, and host companies involved in making the Student Design Awards such a valuable part of the Rotomould26 program. R
Honouring 20 Years of Dedication to ARMA At this year’s Rotomould26 conference, ARMA President Ian Gough had the honour of presenting awards recognising 20 years of ARMA membership. “These awards celebrate the long-term commitment of members whose support helps ensure rotational moulding continues to thrive as a versatile and sustainable industry,” Gough said. ARMA proudly acknowledged five organizations for their continued support: • ARMoulding – with the award accepted by Jason Walker • Persico - with the award accepted by Luca Carrara • Plastics Tanks QLD – with the award accepted by Scott Magill • Reindhardt Teknik – with the award accepted by Dhanu Patell • Suncoast Waste Water Management Their dedication over the past two decades exemplifies the collaborative spirit that drives the industry forward. R
JASON WALKER ARMoulding
Persico
20 YEARS OF
ARMA MEMBERSHIP
DHANU PATELL
Reindhardt Teknik
72 ROTOWORLD® ISSUE 2 • 2026
LUCA CARRARA
ARMO NEWS
Celebrating 50 Years of ARMA
ARMA PAST PRESIDENTS
ARMA’s 50th Anniversary was celebrated throughout Rotomould26, marking five decades of leadership, collaboration, and service to the rotational moulding industry. A special moment during the conference brought together ARMA Presidents, past and
present, in front of the 50 Years of ARMA banner, recognising the people who have helped shape the Association’s journey and the ongoing contribution of members, volunteers, and supporters who continue to strengthen the industry today. R
New Online Training Module Available ARMA are pleased to announce the release of our latest online training module - Rotational Moulding – Moulds and Tooling This course is complimentary for all ARMA members and supporters or $100 per enrolment for nonmembers. The course provides a practical introduction to mould types, tooling methods, powder loading, mould preparation, inserts, breathers, troubleshooting, and mould maintenance. Drawing on real factory examples, it highlights common production issues, contamination risks, and best-practice techniques to help learners
improve quality, efficiency, and confidence in day-to-day rotational moulding operations. The course features: • video demonstrations and written content • a quiz with 1 to 2 questions following each chapter • a certificate of achievement upon scoring 70% or higher To enroll or for more information visit: rotationalmoulding.com/onlinecourses Stay tuned – more online training modules to come! R
www.rotoworldmag.com 73
ARMO NEWS
StAR 2027 Annual Conference & Trade Show The StAR 2027 Annual Conference & Trade Show will take place from 3rd - 5th March 2027 in Gandhinagar (Ahmedabad), India. The theme for the 2027 conference is “Conventional to New Technologies”. Mark your calendar and save the date! More information on www.star2027.com R
JSC Rotational hosts the BPF and Chris Bloore MP JSC Rotational welcomed Chris Bloore, MP for Redditch, and the British Plastics Federation (BPF) to its rotational moulding facility in Inkberrow, Worcestershire, on the morning of Thursday 27 August 2026. In attendance were Karen Drinkwater, Managing Director of JSC Rotational and Past President of the BPF; Richard Hird of the Polymer Machinery Manufacturers and Distributors Association (PMMDA) and UK Sales Director at Labotek; and Mohamed Elkhalifa, Public and Industrial Affairs Manager at the BPF. The visit began with Karen Drinkwater providing an overview of the business. Established in 2003, JSC Rotational provides contract rotational moulding from design through to manufacture, alongside its own PolyJumps range of equestrian equipment. Chris Bloore was given a tour of the site to see the process first-hand. Chris commented: “It was fantastic to see the impressive manufacturing capabilities at JSC Rotational. Supporting local businesses requires clear regulation and a strong focus on apprenticeships, and I look forward to working with
74 ROTOWORLD® ISSUE 2 • 2026
the BPF on these priorities.” Mohamed Elkhalifa outlined the BPF’s political engagement and key policy requests, including support for SMEs to invest in modern, energy-efficient machinery. Discussion then turned to packaging legislation and the state of the UK recycling industry which was underpinned by the importance of a stable predictable regulatory framework that gives manufacturers the confidence to invest. Skills were also high on the agenda. The group discussed apprenticeships, reskilling and upskilling, with a particular focus on helping manufacturers in Redditch and the surrounding area to attract and develop the talent they need. The meeting closed with a productive conversation about potential follow-up, and all parties were keen to continue the dialogue. Overall, the visit was positive and insightful. The BPF would like to thank Karen Drinkwater, Richard Hird, and the JSC Rotational team for hosting, and Chris Bloore MP for his time and engagement with the UK plastics industry. R
ARMO NEWS
ASSOCIATION OF ROTATIONAL MOULDERS AUSTRALASIA LTD Michelle Rose, CAE Chief Executive Officer PO Box 237 Moonee Ponds VIC 3039 Australia Phone: + 61 (0) 404 265 887 michellerose@ rotationalmoulding.com www.rotationalmoulding.com
We are very proud to have been accredited as a Bronze Carbon Literate Organisation. This is part of an ongoing commitment to reduce our organisation’s carbon emissions as well as working with the industry to reduce their carbon emissions. We wanted staff to feel confident talking about the impacts of climate change and reducing carbon emissions. The training inspired staff to look at how we can help reduce emissions for the BPF but also in our personal lives. You may have spotted some initial changes we have made, with trials of vegetarian lunches taking place at events. We are also calculating the BPF’s carbon emissions and looking at how to improve energy efficiency at BPF House. If you have not come across Carbon Literacy before, it is defined as “An awareness of the carbon costs and impacts of everyday activities, and the ability and motivation to reduce emissions, on an individual, community and organisational basis”. It was a really motivating 2 half days of training where we explored how climate change is going to impact on business and how you can mitigate it. The multiple heat waves over this summer, and the wildfires this has led to, have shown in reality the impacts we have to expect in the future without significant action. The BPF will be training more staff this year and we encourage members and all other organisations to look at Carbon Literacy training for their staff. The Carbon Literacy Project has more information on how to become Carbon Literate. R
ASSOCIATION OF ROTATIONAL MOULDING (Central Europe) e.V. (ARM-CE) MAUS GmbH – Rotationsgießformen Am Viehweg 9 - D-76229 Karlsruhe Amtsgericht Mannheim, HRB 103433 Phone: +49 (0) 7 21 / 9 48 74 12 Fax: +49 (0) 7 21 / 9 48 74 44 Mr. Oliver Wandres, ARM-CE Chairman info@rotational-moulding.de www.rotational-moulding.de
ASSOCIATION OF ROTATIONAL MOULDERS SOUTHERN AFRICA PO Box 6966 Birchleigh 1621 Gauteng, South Africa
BRITISH PLASTICS FEDERATION ROTATIONAL MOULDING GROUP
Phone: +27 82 772 3769 Fax: +27 12 541 1738
6 Bath Place Rivington Street London EC2A 3JE United Kingdom
Chairman: Gary Wiid info@armsa.co.za www.armsa.co.za
Phone: 020 7457 5000 Fax: 020 7457 5045 Chairman: Mr. Philip Maddox PhilipM@LeafieldEnv.com
IT-RO ITALIA ROTAZIONALE Katia Zoppetti Via E. Brigatti 12 20152 Milano (MI) Italy Phone: +039 348 7652560 www.it-ro.it
THE NORDIC ASSOCIATION OF ROTATIONAL MOULDERS Executive Board Chairman: Mr. Ronny Ervik ul. Zielona 8, 61-851 Poznań, Poland Phone: +48 607-126-004 Fax: +48 61-858-8611
SOCIETY OF ASIAN ROTOMOULDERS (StAR)
info@rotomoulding-europe.org www.nordicarm.org
Executive Director: SUDEEP SARKAR Plot No. 10, First Floor Hasanpur, 1P Extension Delhi – 110092, India Phone: + 91-011-4701-5924 Mobile: + 91- 9871395183 Mobile: +91-9313308793 sudeep@starasia.org admin@starasia.org www.starasia.org
www.rotoworldmag.com 75
G LO B A L C A L E N D A R
GLOBAL INDUSTRY EVENTS NOV
16-19 2026
ROTOPLAS 2026 & ARM 50TH ANNIVERSARY MEETING Ernest N. Morial Convention Center New Orleans, LA rotomolding.org
APR
NOV
26-27
07-10
2027
2027
2027 ARM EXECUTIVE FORUM Don CeSar St. Pete Beach, FL 33706 rotationalmolding.org
76 ROTOWORLD® ISSUE 2 • 2026
2027 ARM ANNUAL MEETING The Galt House Louisville, KY 40202 rotationalmolding.org
G LO B A L C A L E N D A R
MAR
03-05 2027
2027 StAR ANNUAL CONFERENCE & TRADE SHOW Gandhinagar, Ahmedabad, India starasia.org
SEP
APR
26-28
12-13
2027
2028
ARMO 2027
Grand Hotel Dino Baveno, Lake Maggiore, Italy armo2027.com
2028 ARM EXECUTIVE FORUM
Embassy Suites by Hilton Asheville Downtown Asheville, NC 28801 rotationalmolding.org
www.rotoworldmag.com 77
ADVERTISERS’ INDEX
25 Diversified Mold & Castings 19800 Miles Road Warrensville Hts., OH 44128-4118 USA 216.663.1814 | 888.642.1222 info@diversifiedmolds.com www.diversifiedmolds.com
17 Polymer Link PT 522, Jalan Sultan Mohamed 1, Kawasan Perindustrian Bandar Sultan Suleiman, 42000 Pelabuhan Klang, Selangor, Malaysia. +603 3176 7877 info.my@polymerlink.net.
5 Ferry Industries, Inc. 4445 Allen Road Stow, OH 44224-1093 USA 330.920.9200 sales@ferryindustries.com www.ferryindustries.com
2 Powder King, LLC 41780 N. Vision Way Unit 120 Bldg. 2 Anthem, AZ 85086 USA 623.551.9897 sales@powder-king.com www.powder-king.com
9, 19, 80 Jerico Plastic Industries, Inc. 7970 Boneta Road Wadsworth, OH 44281 USA 330.334.5244 Minerva Plant: 330.868.4600 steve@jericoplastic.com www.jericoplastic.com 11 Matrix Polymers Matrix Polymers Unit 2, Spindus Road, Liverpool L24 1YA United Kingdom +44 151 448 7000 sales@matrixpolymers.com www.matrixpolymers.com 7 Orenda 165 Steelcase Road East Markham, Ontario L3R 1G1, Canada 905.513.8043 sales@orenda-automation.com www.orenda-automation.com 3 OREX Rotomoulding Cieszyńska 6, 43-520 Chybie Poland +48 728 532 382 orex@orex-rotomoulding.com www.orex-rotomoulding.com 48 Poliplast S.p.A. Via Carrali, 8 24020 Casnigo (BG) Italy +39.035.724145 info@poliplastspa.com www.poliplastspa.com
78 ROTOWORLD® ISSUE 2 • 2026
40 Rotaconsult Sydney Australia +61.420.903.039 ianhansenconsult@gmail.com www.ianhansenconsult.com 41 Roto Edge Pro / SMAK 9116 NE 130th Ave, Ste 106 Vancouver, WA 98682 +1.360.882.0410 rotoedge@rotoedgepro.com www.rotoedgepro.com 79 Rotomachinery Group Via Crosa, 53 28065 Cerano (NO) Italy +39.0321.772021 polivinil@polivinil.com www.rotomachinerygroup.com 14 VMP, Inc. 24830 Avenue Tibbitts Valencia, CA 91355-3404 USA 888.4.VMP.INC 661.294.9934 info@vmpinc.com www.vmpinc.com 15 Wittmann Battenfeld Canada Inc. / ROTOLOADTM 35 Leek Crescent Richmond Hill, ON L4B 4C2, Canada 905.887.5355 Toll Free: 1.888.466.8266 info@wittmann-group.ca www.wittmann-group.ca
VOLUME XXII , ISSUE 2 • 2026
PARDON THE INTRUSION
ROTOWORLD
PRINTED MATTER
625 West Market Street Salinas, CA 93901 USA
THE SECRET IS OUT! Jerico is more than just a compounder! We’re making life simpler for Rotomolders everywhere by becoming a strategic distribution partner for PE and PP. You’ve always quality and service, and now that extends to PP and PE in mixed truckloads combined with all of Jerico’s high performance products — anywhere
MANUFACTURING
been able to count on us to deliver excellent
in North America!
Ask us how we can help! info@jericoplastic.com (330) 868-4600
Your Premier Compounder and Distribution Partner for Rotational Molding in North America Proudly Supporting the Association of Rotational Molders! JERICOPLASTIC.COM Committed to Excellence in Rotational Molding • Family-Owned and Operated Since 1997
WWW.ROTOWORLDMAG .COM
Jerico Plastic Industries