RotoWorld 4, 2025_issuu

®

VOLUME XXI, ISSUE 4 • 2025

ROTOTOUR

EAST ASIA 2025

Taiwan, South Korea, and Japan Michelle Rose, ARMA CEO

Tim Leed and Steve Kyval from Melbourne Rotomould reach the top of Mt Fuji in Japan.

OREX ROTOMOULDING

Three Decades of Precision, Innovation, and Sustainable Growth A Company Profile

Designing a Car Wash Kiosk Michael Paloian, Integrated Design Systems

ARM Annual Meeting

Industry Visionaries and Technical Leaders Converge in Dallas Susan Gibson, JSJ Productions, Inc.

A Revolutionary Approach to Rotomoulding – Evolve Aldo Quaratino, Matrix Polymers

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CONTENTS FEATURES

21

21. A revolutionary approach to rotomoulding – Evolve Introducing a new technology.

Aldo Quaratino, Matrix Polymers

48

48. OREX ROTOMOULDING – Three Decades of Precision, Innovation, and Sustainable Growth A story built on passion, courage, and continuous efforts to set a new standard.

A Company Profile

26

26. Designing a Car Wash Kiosk

Demonstrating the many advantages of rotational molding.

Michael Paloian, Integrated Design Systems

On the Cover

32

32. RotoTour East Asia 2025

Traveling to Taiwan, South Korea. and Japan.

Michelle Rose, ARMA CEO

4 ROTOWORLD® ISSUE 4 • 2025

58

58. ARM Annual Meeting

Industry Visionaries and Technical Leaders Converge in Dallas Susan Gibson, JSJ Productions, Inc.

Innovation • Performance • Reliability

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UpFront — K 2025 confirms its pole position as global No. 1 trade fair for the plastics and rubber industries.

C O N T E N T S - D E PA R T M E N T S

At Issue — Rotational Moulding’s Moment: Why Mastering Materials and Skills will Define the Industry’s Future.

18

46

40

Women in Roto — Gaye Kanalti Baş: Research and Development Manager at Floteks Automotive

72

08. FROM THE PUBLISHER It’s a Wrap!

Susan Gibson, JSJ Productions, Inc.

10. CREDITS 12. GLOBAL CONTRIBUTING EDITORS

ARMO News — StARAnnouces Annual Rotomoulding Conference In Delhi, India – February 2-4, 2026

54. ARM REPORT

Roto industry meets in Dallas.

64. ROTO AROUND THE WORLD

Taiwan – Rotomoulding pioneer - TA Fong Plastic Ian Hansen, RotaConsult

Global Contributors, Department Contributors, and Issue Contributors

70. ARMO NEWS

15. UPFRONT

76. GLOBAL CALENDAR

40. WOMEN IN ROTO

78. ADVERTISERS’ INDEX

Industry News, Trends, and Products

Gaye Kanalti Baş– Research and Development Manager at Floteks Automotive Conchita Miranda, Miraplastek – Mexico

46. AT ISSUE

Rotational Moulding’s Moment: Why Mastering Materials and Skills Will Define the Industry’s Future.

Aldo Quaratino, Matrix Polymers

6 ROTOWORLD® ISSUE 4 • 2025

Rotomould 2026 - Save the Date!

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.

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FROM THE PUBLISHER

SUSAN GIBSON JSJ Productions, Inc.

It’s a Wrap!

As the year draws to a close, I extend my warmest wishes to you and your loved ones for a joyful holiday season and a very happy, healthy, and prosperous New Year.

The end of 2025 marks a remarkable milestone for us—the conclusion of our 20th year in publication of RotoWorld®. This achievement is a true credit to our dedicated team, our exceptional Contributors, and the global rotational molding industry, all of whom consistently help make RotoWorld® the leading publication in our field. Year after year, RotoWorld® continues to improve because we challenge ourselves to expand the possibilities of who we are and what we do.

This year, our Contributing Editors delivered engaging, insightful, and thought-provoking content, and for that we are sincerely grateful. We are also thankful for our long-standing collaborations and relationships with regional rotational molding associations around the world. And to the global rotational molding community—thank you for your continued support. You are, quite simply, what we write about.

Looking back, it was a great year for RotoWorld®.

After far too long, we were honored to feature Conchita Miranda, CEO of Grupo Miraplastek in Aguascalientes, Mexico. This profile allowed us to spotlight not only a transformative leader in the rotational molding industry, but a woman who truly understands the business—one who has led her company into a global enterprise and serves as a trailblazer and role model for the industry at large.

Thank you, Conchita.

We featured Rotomoulding Across the World through the perspective of Martin Coles of Matrix Polymers. Few individuals possess Martin’s depth of understanding of both the unique strengths of regional markets and the shared challenges facing our global industry. His view of the future—one of “evolution and resilience”—is both realistic and inspiring. As Martin so compellingly notes, “through the ingenuity of molders worldwide, our industry will remain not just relevant, but essential, in shaping the products of tomorrow.” Thank you, Martin.

8 ROTOWORLD® ISSUE 4 • 2025

Another highlight was our feature on AI-Driven Rotomolding Factories: Showing the Future Is Intelligent Rotomolding, authored by Mark Kearns of the University of Belfast, Northern Ireland. This article may well serve as a defining bridge into the future as manufacturing undergoes a profound transformation and AI becomes the new normal. It reminds us that the next generation of rotomolding factories will be defined not only by advanced technology, but by how intelligently that technology is integrated and adapted.

Thank you, Mark.

In this issue, we are pleased to feature the Association of Rotational Molders Australasia (ARMA) as they have reached new heights—both figuratively and literally—during their 2025 Rototour of Taiwan, South Korea, and Japan. This story underscores just how far our industry has come in expanding educational opportunities and fostering global growth.

Thank you, Michelle.

On a personal note—yet one of reflection and celebration—we pause to honor several industry greats we lost this year: Glen Beall, world-renowned plastics designer and educator; Sherman McKinnis, a trailblazer who helped light the path forward; and most recently, Stephen Copeland, whose kind, steady guidance and extraordinary contributions will be remembered always. Each earned their place in the ARM Hall of Fame for good reason. These remarkable men were instrumental in shaping the growth and success of the rotational molding industry, touching countless lives and companies along the way. They will be deeply missed and long remembered.

As we look ahead, I couldn’t be more excited about the plans we have for the coming year and the opportunity to continue serving the rotational molding industry.

With sincere appreciation,

SUSAN GIBSON Publisher & Editor

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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 JSJ Productions, Inc. 625 West Market Street, Salinas, CA 93901 Phone: (512) 894.4106; Fax (512) 858.0486 Email: rotoworldmag@rotoworldmag.com and Website: www.rotoworldmag.com Subscriptions: One-year subscription (six 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, JSJ Productions, Inc., 625 West Market Street, Salinas, CA 93901 Advertising: For information on advertising, please contact Advertising Director Jennifer Gibson Hebert, JSJ Productions, Inc. Email Jennifer Gibson at jennifer@jsjproductionsinc.com Letters: We welcome letters about our contents. Write Letters to the Editor, JSJ Productions, Inc., 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(R) editorial.

Postmaster: Send changes of address to RotoWorld®, JSJ Productions, Inc., 625 West Market Street, Salinas, CA 93901 RotoWorld® is a JSJ Productions, Inc. independently owned, bi-monthly trade magazine for the international rotational molding and plastics design industries. JSJ Productions, Inc. owns all copyrights 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 4 • 2025

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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

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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 customer’s 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

TOM INNIS

Tom Innis is owner and Principal CEO of Xcelerant Growth Partners, LLC (Madison, WI), a multi-discipline consulting firm with specific focus in the global plastics sector.

Leveraging industry experience and relationships built over 25+ years in the international manufacturing realm, Xcelerant connects the links in the industry supply chain to accelerate speedto-market and deliver turnkey personnel, product development, and manufacturing solutions to an international audience. tinnis@ xcelerantgrowthpartners.com

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 rotomoulding-related patents. Laws is currently a fulltime Manufacturing Engineering professor at BYU-Idaho, as well as CEO of Halltech Systems and High Pointe Plastics. drulaws @gmail.com

www.rotoworldmag.com 13

ISSUE EDITORS

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 highperformance polymers that have revolutionized the rotomoulding industry.

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MICHELLEE ROSE

Michelle Rose is the Chief Executive Officer of the Association of Rotational Moulders Australasia (ARMA), where she has spent nearly two decades guiding, growing, and championing the industry through change.

A natural connector and lifelong learner, Michelle has visited hundreds of factories around the world, gaining an insider’s view of the people, innovation, and quirks that make this global industry thrive. Her leadership blends strategic clarity with genuine care, strengthening governance, building international partnerships, and driving sustainability, training, and advocacy initiatives that support members at every level. Known for her attention to detail and her ability to bring people together, Michelle is a trusted voice in the rotational moulding community and a regular contributor to RotoWorld® magazine.

UPFRONT

Stephen “Steve” Copeland It is with profound sadness that the family of Stephen “Steve” Copeland announces their beloved patriarch’s unexpected passing on Monday, November 10, 2025. Steve leaves behind a legacy defined by devotion, hard work, and generosity of spirit. To know Steve was to know a caring father, a devoted husband, and a man whose drive and compassion shaped every chapter of his life.

Steve was a man who believed deeply in doing things the right way.

He approached life with quiet determination, driven, hardworking, and unwavering in his commitment to providing for those he loved. Whether he was tackling challenges at work or supporting his family through every milestone, Steve gave nothing less than his full heart and effort. His dedication to his company and employees was profound; he cared for them not just as colleagues, but as people whose lives and wellbeing mattered to him. At home, Steve’s greatest joy was his family.

As a loving husband to Brenda and a proud father to Brandi and Adam, he built a life rooted in love, support, and togetherness. He adored being “Pawpaw” to his grandsons, Caleb and Logan, who brought boundless joy and purpose to his days.

He welcomed with open arms his daughter-in-law, Brandi and son-in-law, Rod embracing them fully as family. Anyone who spent time with Steve knew he had a lighter, fun-loving side as well.

Steve never met a karaoke machine he didn’t like, and his voice, full of heart and personality, could light up any room. Those moments of music, laughter, and connection will be cherished forever. Patriotic and insightful, Steve had a way of seeing the world with clarity. His thoughtful perspective, steady guidance, and love for his country shaped countless conversations and left a lasting impression on all who knew him.

Steve is preceded in death by his mother, Norma; father, Bradley; stepfather, Virgil and brother, John.

Though he has rejoined them in peace, he leaves behind a family who will carry his spirit forward with love, honor, and gratitude. He is survived by his wife, Brenda; daughter, Brandi; son, Adam; grandchildren,

Caleb and Logan; daughter-in-law, Brandi; and son-in-law, Rod. He leaves behind his sisters, Carol (husband, Ruben) and Louanne (husband, Joe) his brother, David; his sister-in-lawn Gina, and numerous other family members who loved him dearly and his precious, “Bonnie Blue Belle”.

Steve Copeland will be remembered not only for the extraordinary man he was, but for the warmth, wisdom, and love he gifted to the world. His legacy lives on in his family, in the lives he touched, and in every memory held close by those who loved him.

Steve’s funeral service was held on Tuesday, November 18, 2025, at 1 p.m. at the CampfieldHickman-Collier Home, 566 W. Park Ave., Barberton, Ohio 44203. The family asks in lieu of flowers, please donate in Steve’s name to your favorite charity. R

www.rotoworldmag.com 15

UPFRONT

Diversified Mold & Castings enters 4th Generation of leadership.

Diversified Mold & Castings (DMC), a leader in rotational mold building, is proud to announce the continuation of its family legacy as the company enters its fourth generation of leadership. Vincent Anthony Costello (“Vinnie”) joined DMC full time in 2025, following his graduation from The University of Akron.

Vinnie earned a Bachelor of Science in Automated Manufacturing Engineering Technology, an Associate of Applied Science in Manufacturing Engineering Technology, and a minor in Professional Selling. His academic background, combined with years of hands-on experience at DMC, positions him well for a growing role within the organization.

“Cindy and I are thrilled to welcome our oldest son to the company full time,” said Vince Costello, CEO of Diversified Mold & Castings. “Since his graduation in May, Vinnie has demonstrated dedication, diligence, and a strong work ethic. He is already proving to be a valuable asset to our team.”

Currently serving as an Engineering/Production Assistant, Vinnie spends much of his time in DMC’s CNC department, where he continues to expand his knowledge of CAM programming and manufacturing processes. He also supports other departments as needed and assists with facility maintenance. Having worked part-time at DMC during summers and school

breaks for more than ten years, Vinnie brings a deep understanding of the company’s operations across all departments.

“I’m grateful for the opportunity to continue my family’s legacy at DMC,” said Vinnie Costello. “Having grown up around the business, I’ve seen firsthand the pride our team takes in its work. I’m excited to build on that foundation, learn from everyone here, and contribute to ongoing improvements that help us better serve our customers.”

Vinnie is actively engaged in identifying opportunities for continuous improvement and supports DMC’s commitment to LEAN manufacturing principles, helping ensure efficient, high-quality operations.

As Diversified Mold & Castings enters its 87th year in business, the company is proud to have its fourth generation on board and looks forward to continuing its tradition of quality, innovation, and customer service for many 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, visit www.diversifiedmolds. com R

Sherman Leroy McKinniss (1936—2025) Sherman Leroy McKinniss, beloved husband, father, grandfather, and great-grandfather, passed peacefully into the arms of his Savior in Rancho Mirage, CA, on September 20, 2025, at the age of 89, surrounded by family.

He was born in 1936 in the small township of Hawks, OH, to the late Darrell and Maude (Erwin) McKinniss, the fourth of fourteen children. Sherman attended Marseilles High School, class of 1954, and he married his high school sweetheart, Carol (Hensel).

Sherman excelled at sports in high school and

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beyond. He played basketball, fast pitch softball, and enjoyed fishing, hunting and golf. He was inducted into the Softball Hall of Fame in 1990.

A hard worker from day one, Sherman also made a name for himself as a titan of industry in the field of rotationally molded plastics. His entrepreneurial spirit brought him out to California, where at the age of 38, he became the founder and CEO of Rotational Molding Inc., a manufacturing plant in Gardena. He expanded the company, and at its peak, he presided over 10 locations throughout the United States. Sherman

UPFRONT

dedicated over 40 years of his life to the industry and was a founding member of the International Association of Rotational Molders (ARM). Well-known by many rotational molders to whom he had lent a helping hand; Sherman was inducted into the ARM Hall of Fame in 1997.

Sherman retired to the Palm Desert Greens community, where he became an avid golfer, board President, active community member, and friend to many.

Men of his generation tend to be judged by their professional accomplishments. He excelled in this regard, but he took immense pride in being the patriarch of his family. He led by example and passed along his strong convictions and relentless work ethic. He believed in striving to be the best you can be in every endeavor. He was a doting father to his girls, who loved him dearly and cared for him in return.

His grandchildren fondly remember him as a strong leader, the patriarch of the family, and a force for fun, especially when dressed as Santa for Christmas.

Sherman is survived by his wife Carol and his loving daughters and their families: Brenda (Larry)

DeDonato, and their son Mark (Bethany) DeDonato; Dawn Whitney and her children Danielle (Frank) Moore, Desiree (Mark) Chavez, Ryan Whitney, and Braden Whitney; Margaret Joan (Douglas) Russell and their children Shannon (Richard) Martin, Shari Russell, Leesa (Zachary) Greenawalt, Laura Russell, and Nicole Russell; and Sherri Lee (Mario) Poma and their children Kyle (Chelsea) Poma, Kristine (Jonathan) Rallo, and Gregory Poma. He is also survived by his twelve great-grandchildren.

He is preceded in death by his son-in-law, Robert Whitney, and granddaughter, Carolynne Lee Whitney.

A Celebration of Life was held in the Palm Desert Greens Clubhouse on Sunday, October 5, at 1:30 pm.

In lieu of flowers, the family kindly requests donations be made in memory of Sherman to the Rainbow Services of San Pedro Women’s & Children’s Shelter or the Palm Desert Greens Flag Fund (checks made payable to PDG Flag Fund and mailed to Erma Hanks, 73450 Desert Greens Dr. N., Palm Desert, CA 92260).

Rest in peace, dear Sherman. We will forever hold you in our hearts. R

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UPFRONT

K 2025 confirms its pole position as global No. 1 trade fair for the plastics and rubber industries “The Power of Plastics! Green – Smart – Responsible” as a motto put into practice – sector boasts innovative power, responsibility, and a sense of departure.”

K 2025, the most relevant trade fair for the plastics and rubber industry worldwide, drew to a successful close on 15 October 2025 after 8 days. In view of the current difficult economic climate, many companies in the plastics and rubber industry travelled to Düsseldorf with rather subdued expectations. But the mood prevailing across the fully occupied exhibition grounds proved outstanding on all trade fair days. The plastics and rubber industry presented itself as more innovative, international, and determined than ever to actively shape the transition to more sustainability, digitalisation, and social responsibility.

“K has demonstrated once again just how much innovative power and dynamism this sector holds. The enormous international interest, the high demand for information and the multitude of concrete investment conversations all the way to many contracts concluded right on site underline the importance of this trade fair as a global platform for pioneering solutions and partnership-based exchange,” emphasizes Marius Berlemann, Chief Operating Officer at Messe Düsseldorf, and adds: “K is an indispensable compass in uncertain times and once again succeeded in confirming its role as the most important impulse provider and launch platform for the global plastics and rubber industry, where numerous companies have unveiled their innovations to the global public for the first time.”

Under the strapline “The Power of Plastics! Green – Smart – Responsible”, 3,275 exhibitors from 66 nations presented forward-looking technologies, products, and processes along their entire value chain across 18 exhibition halls and outdoor areas.

Over 175,000 trade visitors from around 160 countries travelled to Düsseldorf meaning that K attendance remained stable. K provided impressive proof of its position as the industry’s most global trade fair: 73% of all visitors came from abroad and over one third of these from overseas. A particularly strong representation was seen from China (6,300 visitors) and India (6,400 visitors). A total of 10,000

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visitors travelled from the US and Brazil to K 2025.

The trade fair again stood out with an above-average ratio of decision-makers (67%).

“The environment we currently have to navigate remains enormously challenging,” explained Ulrich Reifenhäuser, Chairman of the K 2025 Exhibitor Advisory Board. “But it is especially in such times that the strength of our industry becomes visible.

Every three years the global plastics sector comes together here – and for good reason: K is the place where innovations are launched, partnerships are forged, and visions turn into reality. Plastics have been – and will remain – the most important material of our time. They fuse lightweight design, utility, and energy efficiency with versatility serving as pioneers of progress in many applications – from medical technology to mobility and energy supply. With improved recycling solutions and circular concepts, they will increasingly become the most sustainable material of our times.”

With its three central key topics “Shaping the Circular Economy”, “Embracing Digitalization” and “Caring about People” K 2025 struck exactly the right chord with the spirit of the times. Machine and plant builders impressively showed how efficiency, precision, and resource savings can be linked through their ultra-modern manufacturing systems and live demos. The segment of raw and auxiliary materials also convinced the audience with its innovations: from bio-based materials to recycled compounds, to new

UPFRONT

additives that fuse functionality with sustainability, the exhibitors showcased an impressive panoply of solutions for tomorrow’s material development. From highly advanced recycling plants and alternative raw materials to data-driven manufacturing systems, to strategies for talent promotion and resource savings, it was palpable in all halls: the sector has taken up the challenges and works determinedly on solutions.

Visitors from throughout the world came hungry for information: alongside recycling, resource savings, and topics related to circularity, conversations also centered on digitalisation, automation, artificial intelligence, and efficiency increases, in particular.

This year’s event was characterized by high satisfaction levels. According to preliminary survey results, 95% of visitors stated that they had achieved their objectives at the trade fair. 98 per cent of trade visitors rated the range of products and services on offer as excellent or were very satisfied with it. Visitors were especially impressed with the strong presence of market leaders and the multitude of innovators.

The numerous Specials at K 2025 also proved very popular with the international audience. Especially

the official Special Show “Plastics Shape the Future” organized jointly by Plastics Europe Deutschland and Messe Düsseldorf inspired with Expert Talks, panel discussions, and Start-up Pitches on various themed days. Just as compelling was the VDMA Forum “The Power of Plastics”, which presented the technical implementation of circular processes in plastic production with live demos and expert talks. This programme was complemented by the Start-up Zone and Science Campus bringing together innovation and research. By presenting Rubber Street under the patronage of WDK, K once again provided a showcase for the innovative power of the elastomer industry.

With the debut of “Women in Plastics” K sent out an inspiring signal for more diversity, responsibility, and a future-oriented industry. Guided Tours for a wide variety of target groups such as industrial designers or young professionals rounded off the package.

For a detailed review of K 2025 with exhibitor interviews and video footage visit: K-LIVE The next K will be held in Düsseldorf from 18 to 25 October 2028.

For more information, impressions and statements go to www.k-online.com. R

ROTOLOAD™ powder weighing & dispensing systems

» ROTOLOAD™ is the ONLY solution to ALL of your powder resin handling needs. » ROTOLOAD™ is the ONLY comprehensive line of powder resin conveying and weighing equipment, specifically designed to meet the demands of the Rotational Molding Industry. » ROTOLOAD™ uses vacuum to load your material, hold it above your process machine, and dispense, quickly and accurately. In addition it is the ONLY solution to the question of how to reduce under and overweight parts, mess, downtime and resin loss.

Manufactured by Wittmann Battenfeld Canada Inc.: 35 Leek Crescent | Richmond Hill, ON L4B 4C2

www.rotoworldmag.com 19

UPFRONT

INEOS announced a €250m investment programme to regenerate and modernise its cracker at Lavera as part of a bold move to secure the future of one of France’s most important industrial sites and safeguard thousands of jobs.

• INEOS launches a major investment at Lavera to regenerate and modernise one of France’s most important industrial sites, safeguarding 10,000 jobs.

• The project marks the first phase of a long-term regeneration plan to reduce emissions, boost reliability, efficiency and competitiveness, with support of the French State.

• INEOS maintains calls for a level playing field for European industry, warning that high energy prices and carbon costs are driving closures and putting Europe’s manufacturing base at risk.

INEOS has announced a €250m investment programme to regenerate and modernise its cracker at Lavera as part of a bold move to secure the future of one of France’s most important industrial sites and safeguard thousands of jobs.

With backing from the French Government, and facilitated by BNP Paribas and ING, INEOS is investing in the site to improve reliability, boost efficiency and cut emissions. It marks the first phase of a wider regeneration plan designed to strengthen Lavera’s long-term competitiveness and sustainability.

Sir Jim Ratcliffe, INEOS Founder and Chairman, said: “France is showing real industrial leadership.

The government understands that without a strong manufacturing base, Europe will falter. INEOS is investing in Lavera because we believe in the site, its people, and its future but Europe must wake up. High energy prices, over-regulation, and punitive carbon costs are destroying its industrial backbone. If politicians want jobs, investment, and energy security, they must create the conditions for industry to compete. It is as simple as that!”

Sébastien Martin, Minister Delegate for Industry, said: “With this E250investment, INEOS reaffirms its confidence in France’s industrial sector. Thanks to the support of the State, Lavera becomes the symbol of a nation that chooses to produce, innovate, and invest on its own soil. This is how we strengthen our independence, our competitiveness,

20 ROTOWORLD® ISSUE 4 • 2025

and our jobs.”

The Lavera site employs around 2,000 people directly and more than 10,000 through its supply chain. It produces essential raw materials used across almost every manufacturing sector from healthcare and pharmaceuticals to aerospace, transport, food packaging, clean energy, and advanced technologies.

Rob Ingram, CEO of INEOS Olefins & Polymers Europe, said: “This is a vital investment to support continued operations at Lavera, a vital part of the French and European economy. It is about safeguarding jobs, improving performance, and cutting emissions. It is a strong signal of INEOS’ commitment to France, and to keeping essential production in Europe.

The European chemicals and polymers sector continues to face severe pressure from high energy prices, which are three to four times that of China and the USA, and from carbon costs that are only paid in Europe. Multiple plants have already closed across the continent. INEOS warns that unless Europe restores competitiveness, industrial decline will accelerate.

Future phases of the Lavera regeneration programme will deliver further efficiency gains and major CO₂ reductions but will require further support from the French State to bring these plans to fruition.

The Lavera regeneration programme is a vote of confidence in France and European manufacturing – proof that with the right support, industry can thrive, decarbonize, and deliver the jobs and products Europe depends on.

For more information, contact Marie-Pierre, communications manager Lavera t: +33683840398 e: marie-pierre.collin@ineos.com R

A revolutionary approach to rotomoulding – Evolve A L D O Q U A R AT I N O , M AT R I X P O LY M E R S

Even though rotomoulding continues to attract an increasing level of interest globally, it feels like the growth of this extraordinary and versatile polymer processing method is hindered by its long cycle time, limited selection of rotomouldable materials, and inefficient heat exchange. Moulders today are still facing the same issues that moulders were confronted with many years ago: surface pinholes, voids/bubbles, clogged breathing systems, basic design errors, etc. It appears that this flexible way to process resins such as polyethylene, polypropylene, and polyamide has not been transformed by the introduction of revolutionary and advanced technologies that could help to address its known limitations. For example, for many moulders it can be extremely difficult to eradicate pinholes entirely from the surface of rotomoulded articles.

Also, processing cycle time is incredibly long if compared to other plastic processes due to the lack of thermal efficiency in the heat exchange from the burner to the air, to the tool, and finally to the powder.

As a material supplier to the rotomoulding industry, Matrix Polymers has conducted intensive research and studies in order to tackle some of the common issues that many rotomoulders still face today.

In this article, we describe a new technology called Evolve - a technology that could help

moulders avoid pinholes on the surface of their products, shorten cycle time, and reduce gas consumption without sacrificing material performance and product quality.

Formation of pinholes and bubbles

During the rotational moulding heating cycle, the mould containing the powder is typically heated in an oven from ambient temperature to the melting temperature for the resin. When the mould rotates in the oven, its metal wall becomes hot, and the outer surface of the powder particles becomes tacky. The particles stick to the mould wall and to each other, thus building up a loose, powdery mass against the mould wall. A significant amount of cycle time is consumed by the coalescence of the powder until it forms an homogeneous melt; this part of the process is known as the sintering phase.

During sintering, pockets of

air are randomly formed, and these remain trapped between the powder particles. Slowly they transform themselves into spheres, and under the continuing influence of heat over an extended period of time they will eventually disappear.

However, extending the oven cycle to eradicate the surface pinholes and bubbles throughout the wall of the part can result in polymer degradation, which can lead to a loss of mechanical and physical properties.

Once formed, these pinholes and bubbles do not move through the melt. The viscosity of the melt is too great for this to happen, so the bubbles remain where they are formed and slowly diminish in size over a period of time (see Figure 1). Commonly, the only controls on the process are the oven temperature, the time in the oven, and the rate of cooling.

Each of these variables has a major effect on the properties of the end product. If the oven

Figure 1: Formation of pinholes and bubbles

www.rotoworldmag.com 21

is required for bubbles and surface pinholes to disappear.

Evolve is not a flow promoter and does not have any effect on the rheological (viscosity) properties of the resin. It should be noted that other factors may influence the sintering stage of the process such as particle size and its distribution, particle shape, and how the heat is transferred from the oven (burner) to the polymer.

“MOULDERS TODAY ARE STILL CONFRONTED WITH THE SAME ISSUES THAT MOULDERS WERE CONFRONTED WITH MANY YEARS AGO.”

Figure 2: Test mould hex-bin on the Ferry RS 1.90

time is too short, or the oven temperature is too low, then the sintering and consolidation of the resin will not have sufficient time to complete. This results in low impact strength, low stiffness, and a lack of toughness in the end product.

Conversely, if the plastic is heated for too long, then degradation of the plastic will occur and this results in brittleness. In commercial production an easy and practical ‘tool’ used by moulders is to look at the extent to which the moulded articles have pinholes in a small shaving taken through the cross section of the part.

If there are no pinholes and bubbles, then there is a danger that the part has been overheated or heated for too long

22 ROTOWORLD® ISSUE 4 • 2025

and this will result in brittleness.

If there are too many pinholes and bubbles, then the part may be ‘undercooked’. The ideal condition is thought to be a small number of bubbles towards the inner, free surface of the part.

Although the optimum moulding conditions should be established by performing tests on the moulded part to verify whether the material (and the part) achieves the performance levels targeted.

Evolve – its mode of action

Evolve works to accelerate the coalescence of the powder in its molten phase by reducing the surface tension of the bubbles of air which are randomly formed during the sintering phase. This means that less heat (energy)

Test results

As per good manufacturing practices, whenever the chemistry of a material is changed or even slightly modified it is recommended to assess the mechanical and physical properties of the resin. In this study Revolve N-307 (3.5 MFI, 0.939 kg/m3 density) with and without Evolve were compared.

To ascertain the impact properties of the Evolve N-307, rotationally moulded hexagonal bins were produced at various moulding conditions on a Ferry RS1.90 carousel machine as illustrated in Figure 2. The oven temperature was fixed at 250 °C and the oven time was varied.

The rotomoulded hexagonal shaped items were cut in square plaques (125 x 125 x 3 mm) and

120

-40 ºC Impact Strength (J)

100

80

60

40

20

0 7

9

11

13 15 Cook time (min) N-307

17

19

21

17

19

21

Evolve N-307

Figure 3: ARM Impact comparison 120

100

80 Brittleness (%)

then conditioned at -40 °C for 24 hours before being impacted.

The plaques were impacted in accordance to the falling dart method developed by ARM. The ARM Impact strength values at each of the moulding conditions are plotted in Figure 3.

The mathematical model applied to the falling dart test methodology also enables us to calculate the number of brittle failures. This number is plotted against cook time in Figure 4.

By evaluating the number of brittle failures, it is possible to determine a range of moulding conditions within which a good quality resin has zero brittle failure. This determines the operating or processing window of a polymer. By applying the Evolve technology of N-307 it is possible to observe that N-307 reaches the same impact energy but sooner and maintains the

60

40

“BY ACCELERATING THE SINTERING PROCESS, EVOLVE ENABLES MOULDERS TO ACHIEVE THE SAME MECHANICAL PERFORMANCE IN LESS TIME—WITHOUT NARROWING THE PROCESSING WINDOW OR COMPROMISING MATERIAL INTEGRITY.”

20

0 7

11

13 15 Cook time (min) N-307

Evolve N-307

Figure 4: Brittleness comparison

does not influence the short-term properties of the polymer.

Densification same operating window of N-307 without Evolve.

This means that N-307 maintains the same mechanical performance and the technology

9

Another method to assess how the technology influences the sintering stage of the rotomoulding process is to measure the development of the part density. This simple and easy

test is based on Archimedes’ principle. In simple terms, the principle states that the buoyancy force on an object will be equal to the weight of the fluid displaced by the object, or the density of the fluid multiplied by the submerged volume times the gravitational acceleration. At each of the moulding conditions, the density

www.rotoworldmag.com 23

0.945

0.940

Part Density (g/cm )

of a moulded part taken from the hexagonal bin was measured and the performance of N-307 with and without Evolve was measured as shown in Figure 5.

As can be seen in Figure 5, the Evolve technology influences the sintering process to accelerate the removal of bubbles and surface pinholes, allowing the polymer to achieve its nominal density earlier in the cycle.

0.935

0.930

0.925

0.920 8

10

12 14 Cook time (min) N-307

Gas consumption

As described in the mode of action, this technology can reduce the surface tension of the powder in the molten state. Therefore, the powder when molten might require less

24 ROTOWORLD® ISSUE 4 • 2025

18

260

280

Evolve N-307

Figure 5: Part-density development of Evolve N-307 0.942 0.940 0.938 Part Density (g/cm )

“BY INFLUENCING THE SINTERING STAGE OF THE ROTOMOULDING PROCESS, EVOLVE ENABLES THE POLYMER TO ACHIEVE ITS NOMINAL DENSITY EARLIER IN THE CYCLE. THIS IMPROVED THERMAL EFFICIENCY MEANS LESS ENERGY IS REQUIRED TO FULLY CONSOLIDATE THE MATERIAL, RESULTING IN REDUCED OVEN TEMPERATURES, LOWER GAS CONSUMPTION, AND A MORE EFFICIENT OVERALL MOULDING PROCESS— WITHOUT COMPROMISING MATERIAL PERFORMANCE OR PART QUALITY.”

16

0.936 0.934 0.932 0.930 0.928 0.926 180

200

220 240 Oven Temp. (°C) N-307

Evolve N-307

Figure 6: Part Density vs. Oven Temperature

energy to coalesce. To prove this, it was necessary to create a correlation between a material’s property and the temperature of the oven. In this study it was decided to measure the density of a moulded part and monitor the gas consumption required to cook the part at the optimum moulding conditions. N-307 with

and without Evolve was used and hexagonal shape bins were moulded on the Ferry RS1.90 carousel machine. The time in the oven was kept fixed, and the temperature of the oven was varied as illustrated in Figure 6. For each moulding condition, the peak internal air temperature was also measured

Conclusions

As described in this article, the Evolve technology influences the optimum moulding condition of a resin by affecting the sintering process. This leads to a number of potential benefits such as a reduction in the quantity of pinholes and bubbles on the surface and throughout a moulded product, a reduction of cycle time with a potential increase of productivity per shift, and a reduction of gas consumption with a significant reduction of CO2 emissions. In order to assess the advantages of the technology it is required to compare the same polymer without Evolve and establish an optimum moulding condition.

For further information about the Evolve technology please contact the author at aldo.quaratino@matrixpolymers. com R

0.942 0.940 0.938 Part Density (g/cm )

as shown in Figure 7 and the gas consumed was recorded by a gas meter (see Figure 8), located on the back of the Maxon burner within the Ferry machine.

All measurements taken during the analysis are listed in Table 1.

0.936 0.934 0.932 0.930 0.928 0.926 140

160

180 PIAT (°C) N-307

200

220

Evolve N-307

Figure 7: Part Density vs. PIAT

Figure 8: Ferry machine gas meter

PIAT (°C)

N-307

Evolve N-307

Gas (m³)

120

-

-

0.64

148

0.9276

0.9332

1.58

159

0.9271

0.9345

1.72

172

0.9286

0.9372

1.93

185

0.936

0.9389

2.37

190

0.937

0.94

2.81

210

0.939

0.941

3.25

Table 1: Summary of the measurement

www.rotoworldmag.com 25

Designing

A CAR WASH KIOSK M I C H A E L PA LO I A N , I N T E G R AT E D D E S I G N S Y S T E M S

26 ROTOWORLD® ISSUE 4 • 2025

I was involved in the design of a car wash kiosk, shown to the left.

Although this product was designed a number of years ago, I thought it would provide an excellent example, demonstrating the many advantages of rotational molding.

This article will carry you through the evolutionary design and development of this kiosk, which was very challenging to develop.

The story unfolds in the following paragraphs.

I met my client, who was a very energetic, ambiguous young man, in his conference room, along with a few of his key staff members, to get introduced to his unique business and product line. His attention was focused on developing a new generation of a cashless kiosks. He outlined a few of the many critical considerations for the product, the most important being security.

His current product line included various iterations of kiosks, which were manufactured with a complex, waterproof internal steel cabinet, covered with several vacuum-formed external covers. The internal steel cabinet provided a highly secure compartment for all electronic components and cash transactions, while the external thermoformed covers provided an attractive external enclosure.

In addition to appearance, the plastic covers also protected sensitive internal electronic components from excessive heat induced by sunlight by

providing a thermal barrier.

This initial meeting was a critical starting point for the project because many of the critical design parameters were noted and documented. These parameters eventually comprised the foundation of the product specifications, which is an essential first step in the design of any product. In addition to establishing

product specifications, we also discussed the following: • Major design objectives • Review possible product configurations • Define major product requirements • Review schedule • Investment & cost • Discuss marketing objectives

www.rotoworldmag.com 27

All these topics were detailed in a final product specification report before the actual design began.

A summary of the parameters is listed below: • The new module should be easy to assemble • The structure and covers must be aesthetically appealing, setting a new look for the next 10+ years • The new structure will support several components arranged in the image shown • The new modules must be easy to service • The new modules must be easy to assemble and test during production • New modules must be waterresistant to rain • New modules must comply with security requirements • New modules must be very reliable and long-lasting • Kiosks must withstand environmental conditions from Arizona to Alaska

Phase 1 – Product Research and Information Gathering After the specifications were formalized and approved by our client, we started our research phase of the design process by visiting several car wash sites

28 ROTOWORLD® ISSUE 4 • 2025

• Chemical resistance • User interface • Ergonomics • Impact requirements • Installation requirements • Product branding & image • Servicing requirements • Security & vandalism The most significant parameter influencing the overall design was ergonomics. Location and arrangement of all the various monetary transaction devices had to be critically placed, providing optimum accessibility for users seated in a variety of vehicle sizes as shown below.

Phase 2 – Product Ideation and Concept Development

where existing kiosks were installed. These invaluable site visits unfolded critical information that would have a profound effect on the product design.

A brief list of some of these considerations is listed below:

After our investigation and product research were completed, we began generating concepts for the new kiosk. During this initial phase of design, it’s important to maintain an open mind that is tempered with the realities of components, ergonomics, and manufacturability. This is a difficult balancing act since one can become too constrained with technical considerations, which will severely limit creativity. Conversely, complete dismissal of these critical factors during the ideation process could result in completely useless concepts.

The concepts below illustrate a few of the many ideas developed during this phase of design. Each of these accounted for the internal components without being overly concerned about how the product would be manufactured.

The broad array of ideas provided our client with a wide selection of design alternatives, ranging from conservative to very innovative.

Phase 3 – Concept Selection and Detailing

The selection of a design direction was narrowed down after numerous iterative refinements to a basic design concept selected from the concepts presented. The concept below was the proposed final design direction. It was chosen because of its compact embodiment of all the components, ergonomic benefits, simplicity, and characteristics of the current product line brand.

The next challenge was identifying optimal materials and processes that would costeffectively produce the new kiosk.

Brainstorming and analysis led us to conclude that rotational molding would be the ideal manufacturing

maximum structural integrity • One-piece provided a water-tight enclosure • One-piece rotational molded required the lowest tooling investment process for the middle black portion of the kiosk, while vacuum forming would be the ideal process for the front and rear facades. The benefits of rotational molding of the middle section are listed below: • Eliminated many thermoformed parts • Provided one-piece waterproof construction • Simplified installation • Provided thermal insulation • Maximized weather protection • Optimized security requirements • Optimized aesthetic requirements • Significantly reduced assembly time • Most cost-effective option of any process • Minimized tolerance problems • One-piece design provided

Phase 4 – Production Design Detailing

The real work and time are invested in detailing the CAD files for production design. This phase of work is critical for the successful manufacturing of the product.

The center, rotational molded main structure was detailed with a slightly convex surface to avoid any surface irregularities during the molding process. This minor detail was necessary since the sides of the center module were cosmetically important. Although the detail appeared to be minor, it did seriously complicate the tool design, requiring a four-piece tool since the curved sides formed undercuts. It also complicated the CAD modeling and part detailing.

The center module was designed as a one-piece structure, which inherently provided a waterproof part and dramatically simplified on-site assembly. Mounting details for fastening the component to the internal steel frame were included, in addition to features for securing the vacuum-formed covers to the front and back. Considerations for tolerances were included in the clearances provided in mounting holes, which secured the center module to the steel frame and vacuum-formed covers.

Molding and tool design considerations also influenced the design and part features. Since the draft had to be included on all internal surfaces, we split the surfaces of the internal walls to define the precise separation

www.rotoworldmag.com 29

added along the top of the part on either side to disguise the witness line and locate it in an area not easily seen by the casual observer.

Some features of the part geometry required us to violate an important rotational molding design guideline, the 5:1 rule. The

between the two halves of the mold. Since the external sides of the part included a curved surface, forming an undercut, we had to define the location and details of the witness line for the moving mold slides. An intentionally molded recess was

Chamber added to improve flow

5:1 rule suggests that two parallel walls must remain separated by a minimum of 5 times the wall thickness. In the detail shown, it was not possible to adhere to this guideline. However, we successfully achieved our desired expectations because of the funnel cross-section. This shape promoted the flow of powder into the feature, which enabled us to attain a complete fill of the feature.

.9” between external walls- nominal .25 wall for material thickness

Although the 5:1 rule can be trivialized because of its simplicity, it can sometimes be easily overlooked. These cross-sections in the part show areas that had to be modified, enabling powder to freely flow into these features. For example, a chamfer was added to one area and molded in holes were positioned to allow material to freely flow in these areas.

We analyzed the internal volume of the mold to ensure that the capacity of the mold was sufficient to accept the resin powder in an open pour. This analysis is an important step in the design process, which is often referred to as bulk density calculations.

Bulk density calculations are simple to compute with CAD modeling. The following procedure is all that is required.

• Step 1 – Calculate the volume of the mold by simply measuring the volume of the solid unshelled CAD model.

• Step 2 – Calculate the volume of the part by measuring the volume of the shelled CAD model based on the specific wall thickness.

• Step 3 – Determine the ratio of the mold volume to part volume and confirm it is greater than 3:1.

• Also confirm there is sufficient free volume in the mold to store the poured resin. This requires a visual inspection of the part geometry and an educated guess of where the resin would be located.

• Imagine how the resin might be distributed throughout the mold as it is melted and formed into the final part.

The first three steps are easy, but the last two require some understanding of the process and experience.

30 ROTOWORLD® ISSUE 4 • 2025

part and how the parting lines defined in the CAD file were translated into the final mold. A cooling fixture was also created to control shrinkage and maintain dimensional control.

Despite these precautions, the molded parts did not conform to the anticipated L - Solid model R - Shelled CAD model specifications defined in with specified wall thickness the CAD files, resulting in assembly misalignments.

Phase 5 – Molding and First The front vacuum-formed door Article Inspection did not properly align with the After the CAD files were reviewed surrounding enclosure, creating and released for production an uneven gap between the top and tooling, the molds were machined bottom seams. Although this minor and placed on a machine for first problem initially looked like it would article sampling. Inspection of the be easily solved, it became a major molds shows the complexity of the challenge.

This small distortion was not immediately apparent, requiring

many hours of measuring and observation before it was uncovered. I would again like to emphasize the importance of always identifying the root cause of a problem before making any design changes!

Phase 6 – Final Production Product

Designers are often encouraged to change their design when these common problems arise during production, which is a major mistake! The first step in solving these problems is to identify the root cause of the problem. In this case, the root cause was eventually traced to a slight cupping of the rotational molded part which caused the front top edge of the part to sag about ¼” .

After we identified and solved the distortion problem, our molder was able to get into full swing production. Units were molded and eventually assembled at the client’s facility. The resulting product was a major success when introduced into the marketplace. R

www.rotoworldmag.com 31

ROTOTOUR

EAST ASIA 2025

Taiwan, South Korea, and Japan MICHELLE ROSE, ARMA CEO

Tim Leed and Steve Kyval from Melbourne Rotomould reach the top of Mt. Fuji in Japan.

Rototour Mt. Fuji 32 ROTOWORLD® ISSUE 4 • 2025

When the global rotational moulding community comes together, it’s never just about factories, it’s about people, cultures, and ideas. Rototour East Asia 2025 brought this spirit to life across Taiwan, South Korea, and Japan, where 33 attendees representing Australia, Brazil, Canada, China, Kazakhstan, Malaysia, Morocco, the Netherlands, the Philippines, the United Kingdom, and the United States shared 12 days of discovery.

Organised by the Association of Rotational Moulders Australasia (ARMA), Rototour has grown into a flagship event on the international industry calendar. ARMA’s leadership ensures each tour is much more than a travel itinerary, it’s a carefully curated experience that combines professional development, cultural immersion, and the creation of lasting global networks.

This year’s East Asia edition offered a unique balance: factory tours of a variety of moulding companies, encounters with different technologies, academic collaboration with students, and cultural experiences that ranged

University of Shiga Prefecture Visit – Waste Busters Presentation

from ancient castles and temples to bustling fish markets.

Yet the true hallmark of Rototour lies in the connections forged. Over shared meals, long coach rides, and factory floor discussions, strangers became colleagues, colleagues became friends, and by the final dinner in Kanazawa, the group had transformed into what many fondly call the Rototour family.

Taiwan | Industry and History Intertwined

Shindo Factory Visit

Rototour East Asia began in style at The Grand Hotel Taipei, a landmark that set the tone for the journey ahead. After receiving their attendee packs, the group was treated to a private tour of the hotel’s West Secret Tunnel,

PCC Lining Factory Visit

www.rotoworldmag.com 33

once an emergency escape route for President Chiang Kai-shek.

It was an early reminder that this tour would always be about more than factories, it was about stepping into the hidden layers of history and culture alongside industry.

The first full day in Taipei showcased that mix perfectly.

Lunch at Shi-Yang Tea House, nestled in the mountains, was an exercise in Zen philosophy: no set menu, just a creative sequence of dishes that encouraged reflection, connection, and an appreciation of simplicity. From there, the group explored the National Palace Museum, home to one of the world’s largest collections of Chinese art and history, before gathering at Silks Palace for dinner.

Of course, Taiwan also delivered when it came to industry. The first factory visit took the group to Ta Fong Plastic Co., Ltd, pioneers in plastic moulding since 1968.

Specialising in sustainable, highcapacity water storage, Ta Fong demonstrated how a traditional manufacturer can reinvent itself for modern challenges.

The afternoon continued at Bear Power Plastic Technology, where eco-friendly bins, tanks, and custom products showed the adaptability of rotational moulding to tough environments.

The Taiwan leg ended with a visit to PCC Rotolining, specialists in advanced corrosion protection using seamless PE fusion lining for steel pipes and tanks, a technology critical to infrastructure longevity in water, gas, and petrochemical industries.

What stood out just as much as

34 ROTOWORLD® ISSUE 4 • 2025

the technology was the hospitality and care shown at every stop.

Each factory welcomed us not only with technical excellence but also with warmth; spotless facilities, staff who greeted us with genuine friendliness, and gestures that bridged language barriers with ease. At one visit, trays of homemade bakery delights appeared, reminding us

Shirawaka-go Village Visit

that the pride of these companies is not only in their products, but also in how they host their guests.

It was these thoughtful touches that made Taiwan’s factory visits memorable on a personal level as well as a professional one.

But perhaps the most memorable moment in Taiwan was one rooted in personal connection. Harry Huang from

Demiliterized Zone Tour South Korea

Celebrating Wouter’s birthday Korean BBQ style

Noryangjin Fish Market

Grand Hotel Taiwan

Kyoto Ninja Food Walking Tour

Any opportunity for a laugh and a photo op!

Shindo Factory Visit STOP!

Wuxi Yisong Rotomolding Technology, who had helped ARMA plan the Taiwanese program, welcomed the group to his hometown of Chiayi, hosting a surprise dinner. That evening, competitors sat at the same table, laughing, talking, and sharing insights. For the first time, the rotational moulding industry in Taiwan came together not in competition, but in collaboration.

When ARMA first visited Taiwan to prepare for the tour, the industry was fragmented, with factories working in isolation and rarely communicating with one another. ARMA changed that.

Factory owners attended each other’s site visits. Knowledge flowed across tables. Our purpose, to represent and support the industry by providing a community for collaboration, education, and innovation, came to life in the most tangible way.

The impact was felt so strongly it even made the local Taiwan news.

By the time the group boarded their flight to Seoul, Taiwan had already delivered the perfect introduction: a country where heritage, hospitality, and industry meet in harmony, and where Rototour sparked the beginnings of a stronger, more connected local industry.

South Korea | Innovation Meets Tradition

From the moment the group touched down in Seoul, the pace of Rototour shifted up a gear. South Korea offered a packed itinerary where industry visits sat side by side with powerful cultural and historical experiences.

The industrial program began at Shindo Industry, South Korea’s

36 ROTOWORLD® ISSUE 4 • 2025

Lift Selfie

Takagi Seiko Factory Visit

Michelle Rose, ARMA at A-IL Plastics Factory Visit. Now THAT’S a tank!

Shirawaka-go V Professor Toshio Igarashi, University of Shiga Prefecture and Michelle Rose, CEO ARMA

leader in road safety equipment.

Watching traffic cones, crash cushions, and other safety products being moulded with precision underscored how rotational moulding protects lives on roads worldwide. The tour continued with A-IL Plastics

Industrial Co., with more than four decades of expertise in rotational and injection moulding for tanks, pipes, and energysaving systems. The final stop was Rototec Co., Ltd., a developer in rotational moulding solutions for outdoor equipment and water

storage. Each visit highlighted South Korea’s ability to pair technology with durable, practical solutions for both industry and community.

Just as in Taiwan, the hospitality of our hosts left a lasting impression. Factory teams welcomed the group with warmth, professionalism, and pride in their operations. Seeing this commitment firsthand, deepened our understanding of how South Korea has positioned itself as a hub for both reliability in plastics manufacturing.

Culturally, the Korean leg of Rototour was just as unforgettable. A visit to the Demilitarized Zone (DMZ) gave the group a sobering but fascinating

glimpse into the ongoing division of the Korean Peninsula. One of the most memorable moments was the 25-storey descent into the Third Tunnel, a passage once dug by North Korea beneath the border, an eerie, tiring walk that brought the realities of their history into sharp focus.

This was balanced by the colour and energy of Seoul itself: wandering through Gwangjang Market to taste traditional street food, choosing fresh seafood at the iconic Noryangjin Fish Market to have it cooked on the spot, and enjoying a Michelin listed Korean barbecue dinner at Samwon Garden. Free time in Myeongdong for shopping and the dazzling Starfield Library at COEX Mall

added another layer of cultural flavour.

For partners, ARMA also curated tailored experiences, from temple tours to palace visits, ensuring that everyone found something meaningful during their time in South Korea.

By the time the group checked out of Seoul, Rototour had once again shown its value beyond the technical: factories opened doors, cultures opened hearts, and our travelling community grew stronger with each shared experience.

Japan | Modernisation, Precision, and Shared Learning Japan welcomed the group with a sense of calm and curiosity.

Dinner at the Noryangjin Fish Market

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Arriving in Osaka, we were treated to a warm evening meal and time to acclimatise, before moving on to the full rhythm of travel, industry, and culture.

Kyoto followed, with its serene temples, gardens, and a walking food tour that introduced attendees to Kyoto’s refined culinary artistry, delicate umami, seasonal vegetables, and subtle flavour balances. Along the way, a multitude of sake varieties were tasted, each glass offering a new note of craftsmanship and tradition. Every dish and drink seemed to echo Japan’s overall harmony of tradition and progress.

One of the first industrial stops was Suiko Co., Ltd., a company with very impressive scale and breadth. Suiko produces rotationally moulded plastic tanks ranging from 20 litres up to 50,000 litres, along with custom pieces, safety and industrial equipment, playground structures, agricultural & livestock products, and more.

What struck our group was not just the scale, but their very high standard of facility cleanliness, organisation of workflow, and the precision with which they handle both small batch custom orders and large volume, highly technical moulded tanks (including those for food and chemical safety).

Takagi Seiko was equally impressive, embodying next level organisational excellence and technological advancement. Their factory layout is streamlined with dedicated zones for design, mould making, finishing, quality control, and logistics. As we toured, it was clear that production lines are carefully planned: machines were arranged to minimise material

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Bear Power Factory Visit

Marthijn keeping warm

handling, safety protocols were deeply embedded, digital support systems used for tracking and workflow optimisation, and sustainability practices visible in waste and energy management.

University of Shiga Prefecture – Students Shaping the Future

One of the most meaningful moments of the Japan leg was our visit to the University of Shiga Prefecture (USP), set near the shores of Lake Biwa, a lifeline for 14 million people and home to more than 1,000 species of animals and plants.

We were welcomed by the Waste Busters, a student led initiative from the Department of Polymer and Composite Materials. Their motto, “Science in Action – Cleaning, Recycling, Teaching,” reflects their mission to turn scientific knowledge into community impact.

For our group, the highlight was their work on rainwater tanks. Using recycled plastics

Welcome Sign Ta Fong Factory Visit

blended with virgin PE powder, the students created a 100-litre prototype tank in partnership with local contractors. These tanks not only reduce plastic waste but also provide sustainable water storage for daily use and serve as mobile supplies during disasters.

Looking ahead, the students

are experimenting with biomassbased additives, such as rice husk silica, to strengthen plastics and extend durability, an inspiring example of how sustainability and innovation can advance together.

The afternoon visit wasn’t just a presentation; it was a dialogue across generations and cultures.

ARMA members contributed industry expertise, while students offered fresh ideas for the future.

We were also fortunate to be given a tour of their laboratories and facilities, where the students’ work in recycled plastics and the associated equipment was displayed. Seeing their prototypes and experiments up close gave our group a deeper appreciation for both the challenges and the ingenuity driving their projects.

A heartfelt thank you goes to Professor Toshio Igarashi, whose leadership and vision made this collaboration possible, and whose commitment to connecting academia with industry perfectly reflects the spirit of Rototour.

By the end of the Japan leg, the picture was clear: Japan is a place where precision isn’t just a technical ideal, but a lived value; where factories are as much about respect for process, people, and environment as they are about throughput.

And Rototour, through ARMA’s orchestration, allowed us to see that every cultural taste, every technical moment, every student project is part of a shared future.

For some delegates, the adventure didn’t stop when the tour officially ended. A group took on the momentous climb of Mt Fuji, Japan’s highest peak and an enduring symbol of resilience and spirit. Standing at the summit at sunrise, they carried with them

not just the Rototour flag signed by their tour family, but with pride of the climb, and the shared sense of achievement that had defined the entire journey. It was a fitting finale to a tour that challenged, connected, and inspired at every step.

“ROTOTOUR IS, AT ITS CORE, ARMA’S PURPOSE IN ACTION: TO REPRESENT, CONNECT, AND SUPPORT THE ROTATIONAL MOULDING INDUSTRY.”

Connections, Impact, and the Spirit of Rototour

Across Taiwan, South Korea, and Japan, Rototour East Asia 2025 proved that these journeys are so much more than factory visits.

They are opportunities to see the industry from new perspectives, to witness how different cultures approach manufacturing and problem solving, and to strengthen the bonds that make our global community unique.

For the 33 delegates who joined, the benefits were many: access to factories rarely open to international visitors, insights into emerging technologies and processes, exposure to new markets, and the chance to exchange ideas with fellow leaders who together represent

hundreds of years of industry expertise. Yet perhaps the greatest benefit was one that can’t be measured on a technical sheet, the friendships, trust, and collaborations that form when people travel, learn, and share experiences side by side.

Equally important, Rototour was also about giving back. We visited countries that had never opened their doors to groups like ours, countries ripe for new relationships and collaborations.

At every stop, we shared our knowledge, experiences, and ideas, showing that this industry is stronger when it works together rather than in isolation.

In Taiwan, we saw competitors sit down together for the first time, turning fragmentation into collaboration. In South Korea, we paired sobering history with vibrant industry, a reminder of resilience and progress. In Japan, we connected academia and industry in a way that inspired both students and seasoned professionals, and even saw some delegates conquer Mt Fuji in a final act of challenge and camaraderie.

Rototour is, at its core, ARMA’s purpose in action: to represent, connect, and support the rotational moulding industry by fostering collaboration, education, and innovation across borders. Each tour builds not just knowledge, but also a community that stretches far beyond geography.

As Rototour East Asia comes to an end, the journey is far from over, in 2026, a new country, new factories, and new friendships await, ready to shape the next chapter of our global adventure. www.rototour.com R

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WOMEN IN ROTO

CONCHITA MIRANDA Miraplastek – Mexico

GAYE KANALTI BAŞ

Research and Development Manager at Floteks Automotive In this second interview for Women in Roto, we travel to Turkey to meet Gaye Kanalti Baş, Research and Development Manager at Floteks Automotive and its spin-off company Pressura. An R&D leader with a background in chemical engineering, polymers and composites, and an MBA, Gaye has spent more than a decade exploring innovation in the automotive and rotomolding world in her native Turkey. She is passionate about sustainability, continuous learning, and supporting others in their growth. Outside of work, she enjoys life with her husband, their dog, and four kittens — who keep every day full of balance and joy.

Could you tell us about your current role, the companies you work with, and where they’re based?

I serve as the Research and Development Manager at Floteks Automotive and its spin-off company Pressura, both based in Bursa, Turkey. Floteks is recognized as one of the leading companies in the rotomolding industry, particularly within the automotive sector. In my role, I am responsible for developing innovative materials, products, and processes that address the evolving needs of global automotive customers.

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“MY JOURNEY IN THIS INDUSTRY HAS BEEN BOTH FASCINATING AND FULL OF CONTINUOUS LEARNING.”

What first drew you to the world of rotational molding, and how did your journey in this field begin?

I have always been passionate about new materials and processing technologies. Before joining Floteks Automotive, I

worked for five years in the automotive industry. My real introduction to rotational molding came during my interview with Celal Beysel, the founder of Floteks and a globally respected rotomolder who has been honored with the Rotational

WOMEN IN ROTO

Molding Hall of Fame Award. I still remember the excitement I felt as he explained the unique potential of this technology and Floteks’ pioneering role in the industry. In that moment, I knew I had found the right place to be.

How has your career developed within the rotational molding industry, and what experiences have been most defining along the way?

My journey in this industry has been both fascinating and full of continuous learning. I started as Research and Development Manager at Floteks, a pioneer of rotational molding in Turkey and a company internationally recognized for its innovation in plastic technologies. In this role, I worked closely with major commercial and heavy-duty automotive OEMs, which was an exciting new challenge after five years in the passenger vehicle sector.

When Floteks established Pressura, focusing on advanced composite pressure vessels, I had the opportunity to lead product and process development from the ground up. Being part of this journey has been especially rewarding — seeing an idea turn into a product that contributes to the future of clean energy is truly inspiring. As a woman in a field where female voices are still rare, it feels meaningful to know that my work not only advances technology but also represents progress toward greater diversity. What motivates me most is knowing that our efforts are helping to build safer, lighter, and more sustainable solutions for everyday life.

Floteks has a long history of innovation. What do you think truly sets the company apart in the industry?

Floteks’ story began in 1978 with a simple idea — bringing innovation to plastics. Just a few years later, it became the first company in Turkey to produce plastic diesel tanks using rotational molding, paving the way for an entirely new industry in the country.

believing that diversity strengthens both innovation and workplace culture. At the same time, Floteks has always placed research, development, and continuous improvement at the center of its growth. More than 20 years ago, Floteks established an R&D department, which later became a legally recognized R&D Center by the Scientific and Technological Research Council of Turkey. Since then,

“WHAT MOTIVATES ME MOST IS KNOWING THAT OUR EFFORTS ARE HELPING TO BUILD SAFE, LIGHTER, AND MORE SUSTAINABLE SOLUTIONS FOR EVERYDAY LIFE.” What makes Floteks unique is not only its technology but also its values. The company prioritizes recruiting and supporting women employees,

the company has completed numerous national and international projects, developing new products, exporting licenses, and contributing to European

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WOMEN IN ROTO

Union research programs — including cooperation with many partners over the last 13 years to complete six EU projects with a total budget of around 13 million Euros.

From a personal point of view, working at Floteks has also been a privilege because of its strong ties to the Association of Rotational Molders (ARM). Through this, I have had the opportunity to meet and learn from invaluable experts such as Paul Nugent, Aldo Quaratino, Gareth McDowell, Ian Hansen, John Steele, Conchita Miranda, Danu Patell, and Konstantia Asteriadou. Having the opportunity to sit across the table from people who shaped the industry, to hear their stories, and to contribute my own perspective has been one of the most rewarding aspects of my career.

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Have there been mentors or role models who have played an important role in shaping your professional path?

Yes, absolutely. My first mentor and guide was Celal Beysel, the founder of Floteks, whose vision and passion for innovation deeply influenced me. I was also fortunate to be inspired by the leadership of his son, Mehmet Beysel, who has been part of the company for over 20 years and knows every detail of it by heart.

Their dedication to education and continuous learning has had a lasting impact on me.

Because of their example, I felt inspired to continue investing in my education. After completing my bachelor’s and master’s degrees in chemical engineering and later an MBA, I had thought my academic journey was complete. But being at the heart

of so many innovative projects reignited my curiosity and drive to learn, and I began my Doctorate in Polymer and Composite Engineering. Beyond education, their leadership has also shown me how to guide my team — not just as a manager, but as the kind of leader they truly deserve.

As a woman in the rotomolding industry, having mentors like them has meant a lot. Their support gave me the confidence to trust myself, even in moments when I felt outnumbered or uncertain.

Knowing they believed in my potential encouraged me to keep learning, take on new challenges, and step forward as a leader.

That guidance has been a big part of helping me find my own voice in this industry. I believe mentorship can open doors, and every woman deserves to have that support to grow and thrive in her career.

WOMEN IN ROTO

As a woman in a traditionally male-dominated industry, what challenges have you faced, and how have you managed to overcome them?

Being a woman in the rotomolding and automotive industry hasn’t always been easy. Early on, I often felt I had to prove myself more to be taken seriously and work harder to earn the same level of trust.

What helped me was persistence, support from mentors, and letting results speak for themselves. Each successful project built my confidence and showed me that my own leadership style — combining expertise with empathy — was a strength.

Those challenges shaped me into the leader I am today. If sharing my journey makes the path a little easier for the next woman in this industry, I consider that one of my most meaningful accomplishments.

Looking back on your career so far, what achievements or moments are you most proud of?

I feel fortunate to have experienced many proud moments in my career so far.

One of the most meaningful has been seeing my team members successfully complete their master’s degrees — knowing that I was able to encourage and support them through such a demanding journey made me incredibly proud.

I also take great pride in the everyday achievements: every time we complete a challenging project and see positive test results, or when we sit down with a customer and deliver exactly the solution they need. These moments remind me why I love what I do. For me,

“MY ADVICE TO WOMEN WHO WANT TO ENTER OR GROW IN THE ROTATIONAL MOLDING INDUSTRY IS TO BELIEVE IN YOURSELF AND YOUR IDEAS, EVEN WHEN YOU FEEL OUTNUMBERED.” pride doesn’t come from a single milestone, but from the many successes — big and small — that I share with my team.

Balancing demanding work with personal life can be challenging.

How do you maintain that balance?

At Floteks, work–life balance is truly valued, and that has made a big difference for me. Of course, there are days when I carry ideas about new projects home with me, but I’ve learned that this often leads to creative solutions — and even a better night’s sleep.

Outside of work, my husband and I share our home with one dog and four kittens, who bring us so much joy. Having loved ones waiting for you — whether on two legs or four — is a daily reminder of the importance of balance, and it gives me the energy and clarity to lead and innovate at work.

What advice would you offer to women who aspire to grow within the rotational molding industry?

My advice to women who want to enter or grow in the rotational molding industry is to believe in

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WOMEN IN ROTO

yourself and your ideas, even if at times you feel outnumbered. This is an industry where curiosity and problem-solving really matter, so don’t hold back from asking questions or suggesting new approaches — your perspective is valuable.

Also, don’t be afraid to lean on others. Find mentors, learn from colleagues, and surround yourself with people who lift you up. There will be moments when you feel you need to prove yourself more than others, but every challenge you overcome will build your confidence.

Most importantly, stay true to your own style of leadership.

Technical skills are important, but empathy, collaboration, and persistence are just as powerful.

The industry needs more women, and there’s a place here for you.

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Looking ahead, how do you see the future of rotational molding, and what role do you hope to play in shaping it?

I see a very exciting future for the rotational molding industry.

With the global shift toward sustainability, lighter materials, and clean energy, rotomolding has enormous potential to adapt and grow. From automotive applications to energy storage and infrastructure, the technology will continue to find new ways to meet the demands of a changing world.

Personally, I hope to play a role in driving that innovation forward. My focus is on developing new materials, processes, and products that not only serve today’s needs but also support the transition to cleaner and more sustainable

solutions — like hydrogen and CNG storage. At the same time, I want to encourage more women to take part in this journey. For me, the future of the industry is not only about technology, but also about building a more diverse and inclusive community that will shape the next chapter of rotomolding.

It’s been a pleasure getting to know inspiring women like Gaye Kanalti Baş from across the globe. Each conversation reveals new perspectives, shared challenges, and the remarkable creativity driving our industry forward. I look forward to continuing this journey — meeting more incredible women and sharing their stories with Rotoworld® readers around the world. R

DIVERSIFIED MOLD & CASTINGS

CNC Molds

OVER

Fabricated Molds

Cast Aluminum Molds

YEARS STRONG

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AT I SS U E

ALDO QUARATINO Matrix Polymers

Rotational Moulding’s Moment: Why Mastering Materials and Skills will Define the Industry’s Future Rethinking a “Simple” Process

Rotational moulding has long been celebrated as the practical, lowpressure method for creating hollow plastic products. By heating a measured quantity of plastic powder inside a rotating mould, manufacturers achieve smooth, uniform walls without the need for expensive, high-pressure tooling.

The result? A remarkably flexible process capable of producing everything from tiny hearingaid components to 70,000-liter storage tanks, plus toys, kayaks, medical parts, and traffic cones.

Low tooling costs and modest machinery investment make rotomoulding ideal for short production runs, something injection and blow moulding can rarely achieve economically.

The process naturally creates consistent wall thickness and strong, reinforced corners, making it especially suited to lightweight, thin-walled products.

And yet, despite its versatility, rotational moulding has remained a niche technology, representing just 1% of global plastics production. The biggest reason: it’s near-total reliance on polyethylene, which accounts for a staggering 98% of rotomoulding materials. That single-polymer dependency has limited the industry’s reach, but it doesn’t have to stay that way.

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Beyond Polyethylene: The Next Frontier

For rotomoulding to grow, the industry must broaden its material portfolio. But new polymers alone won’t spark progress. Success also depends on people specifically, machine operators with the knowledge to mould these materials correctly and safely.

Today, many rotomoulding operations still depend on labour-intensive equipment and demanding working conditions: heat, dust, and physical strain. Attracting and training the next generation is an ongoing challenge and an opportunity. Passing down hands-on experience is essential, yet expertise often remains

AT I SS U E

siloed. One moulder may excel in automotive parts, another in tanks, another in marine applications. Very few operate confidently across all sectors and materials.

The truth is simple: while rotomoulding is versatile, not all polymers behave the same. A material designed for long-term creep resistance in water tanks differs fundamentally from one meant for high-impact kayaks or from polymers required to transport fuel safely and meet regulatory standards. Operators must understand how these materials perform inside the mould and how processing decisions affect product longevity.

The Knowledge Gap on the Factory Floor

During site visits around the world, one issue stands out: operators often know little about the very materials they’re moulding. They excel at the basics cleaning flanges, protecting mould surfaces, keeping vents clear, but lack the tools to ensure optimum material performance.

Do they know whether the polymer inside their mould has reached its ideal processing window? Do they understand how to measure it?

Peak Internal Air Temperature (PIAT) is a valuable processcontrol parameter, but only when validated. Techniques such as ARM’s cold falling dart test remain essential. Another underused method is the part-density test, a simple, cost-free assessment based on Archimedes’ principle.

It quickly reveals porosity and bubble content key indicators of moulding quality.

“FOR ROTOMOULDING TO GROW, THE INDUSTRY MUST BROADEN ITS MATERIAL PORTFOLIO.”

These easy-to-use tools can dramatically elevate material understanding, enhance product consistency, and reduce scrap rates. Yet many moulding shops do not employ them.

Raising the Bar: Skills, Materials, and the Future

The future of rotational moulding will not be defined by machinery alone, nor by polymers in isolation. It will be shaped by

the combination of smarter materials, well-trained operators, and simple yet powerful testing techniques that ensure every part meets both manufacturing specifications and customer expectations.

Rotational moulding has the potential to break out of its niche.

To get there, the industry must expand its material horizons and invest equally in the people who bring those materials to life. R

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A COMPANY PROFILE

Three Decades of Precision, Innovation, and Sustainable Growth

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A

30th anniversary is undoubtedly a special milestone— an opportunity for reflection, evaluation, and a chance to look both back and ahead. For OREX ROTOMOULDING, however, this anniversary holds even greater significance. It represents far more than a number; it reflects our story, built on passion, courage, and continuous efforts to set new standards in our industry.

It is the story of a company that began in a garage and, over the years, has grown into a renowned manufacturer of rotomoulding machines and comprehensive technological solutions.

Przemyslaw Orlik - Managing Director

As our owner recalls: “My name is Przemysław Orlik, and for 30 years I have been developing OREX ROTOMOULDING. I represent the second generation of my family to run this company.

The strength of our team lies in communication and relationships.

Over the years, we’ve had the pleasure of meeting hundreds of rotomoulding business owners, machine operators, and specialists in the rotational molding process, listening to their needs and challenges. As a machine manufacturer and a rotomoulder myself, I deeply understand the expectations and demands of this industry.”

Mr. Orlik’s words capture the essence of our company—a family-oriented approach, a sense of responsibility, and development driven by a clear vision passed from generation to generation.

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From a Local Garage to a Global Business

In its early days, OREX ROTOMOULDING was a small company with big ambitions.

Initially, our work focused on designing technologies for rotomoulding machines. Over time, we expanded into producing our own rotationally molded products and operated as a rotomoulder for two decades.

This experience proved essential for our later success.

It gave us firsthand insight into the production process from the user’s perspective and helped us understand what solutions the market truly needed. As a result, our machines are defined not only by innovation but, above all, by practicality, reliability, and intuitive operation.

Today, our company serves customers in dozens of markets around the world, with machines operating on every continent. Our

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headquarters is located in the small town of Chybie in southern Poland, housed in a unique, 140-year-old former sugar plant. Carefully renovated over the years, the building blends historic industrial character with state-of-the-art technologies. It perfectly reflects the philosophy behind our business—respect for tradition combined with a constant drive for innovation.

Our Values

Over the last three decades, OREX ROTOMOULDING has grown dynamically, yet certain core elements have remained unchanged: our passion for what we do, our precision in how we do it, and our commitment to partnership and responsibility.

These values are the foundation of why customers see us not only as a machine supplier, but as a technological partner in their own development.

Our motto, “Precision in the process,” perfectly expresses how we operate. It reflects not only our attention to construction details, but also the quality of our relationships, our understanding of customer needs, and our responsible approach to project execution. This precision is evident at every stage—from initial concepts and design, through machine construction, to after-sales service and technological support.

Innovations That Set New Standards

One of OREX ROTOMOULDING’s key competitive advantages is the presence of all major departments under one roof, enabling efficient communication, faster decision-making, full production oversight, and flexible project customization.

Our facilities include: Machinery Manufacturing, Automation,

Molds, Steel Processing Center, and—where every project begins—the Design Department, home of our “From Design to Effect” program.

Our flagship products are our CAROUSEL and SHUTTLE machines, which we have refined in recent years to deliver top-tier quality and operating efficiency.

Their technical solutions provide exceptional precision and operational stability, even during the most demanding processes. Continuous investment in technology ensures excellent energy efficiency and outstanding reliability. These machines form the foundation of our portfolio and exemplify our commitment to premium solutions.

Key features that distinguish our machines include: • SIEMENS servomotors for

precise positioning and smooth arm movement—essential in automated processes. (For the American market, Allen-Bradley components from Rockwell Automation are also used.)

• Dual thermocirculator two independent heating channels, which allow for a

more effective heating of the molds • SAFETY System with advanced scanners for secure zones in front of the heating and cooling chambers • Cooling chamber with fully automatic door closure • Proprietary OREX

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ROTOMOULDING software on a large touchscreen interface • SIEMENS control systems • Long, heavy-duty arms designed for large and heavy molds • RITTAL air-conditioned control cabinets …along with many other elements reflecting the high standards of our machines.

Projects and Industry Collaboration

OREX ROTOMOULDING works with companies across a wide range of industries, including manufacturers of industrial tanks, municipal components, automotive and construction parts, as well as companies specializing in chemical, water, and wastewaterrelated products.

Year after year, more sectors adopt rotomoulding, driving further development of the

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technology. Many people are unaware of how many everyday objects around them are created using this process. Every city and town relies on playground equipment and various forms of public infrastructure shaped by rotational molding. The agricultural and agri-technical sectors also continue to grow, introducing new products adapted to modern production methods.

Support at Every Stage

One of the greatest advantages of partnering with OREX ROTOMOULDING is our comprehensive, end-to-end project approach. We do more than supply machines—we support customers through every stage of product development.

Our team assists with concept analysis, cycle design, parameter selection, production launch, and process optimization.

This partnership-based model ensures that customers receive solutions tailored to their real needs, significantly improving manufacturing efficiency.

Our Future: The American Market and AI

The coming years will mark a period of bold expansion and innovation for OREX ROTOMOULDING. One of our key strategic goals is entering the American market—one of the world’s most demanding yet most promising regions for industrial technologies. We have been preparing for this step for some time, carefully studying market specifics and laying the groundwork for continued global growth. R

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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.

Roto Industry Meets in Dallas: 375+ at ARM Annual Meeting

More than 375 people attended the Association of Rotational Molders’ 2025 Annual Meeting in Dallas last week. For three days, manufacturers, suppliers, and educators met to share ideas, learn from

Dr. Nick Henwood

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Adam Covington

one another, and strengthen connections across the rotational molding industry. Feedback was overwhelmingly positive: people valued the sessions, tours, and time spent with peers.

Tony Short

ARM REPORT

Dru Laws

Denis Rodrique

“Great for new members and young roto people to get exposure and meet others in the industry.” — Daren Balderson, Tank Holding “The networking provides key components to our success. Every time I have attended ARM events, I leave feeling energized and focused on improving our business and methods. ” — Corey Eystad, Rhino Inc. “You always take something away from the ARM meetings no matter how long you’ve been involved.” —

Lanhe Zhang

Jim Henry, Diversified Mold & Castings “I really enjoyed the ARM Conference 2025… it’s the best bang-for-our-buck event my company attends.” — Caleb McHenry, Ritchie Industries Inc. “Really enjoyed the family atmosphere. Felt very welcomed by all. Thank you for having us!”— Emily Miller, Mold In Graphic Systems R

ARM Announces 2025 Award Winners After the sessions and networking events at our Annual meeting in Dallas, ARM presented the 2025 Awards on October 1, recognizing the year’s outstanding work in leadership, safety, design, and service. We’re sharing the news now and will update our blog soon with photos from the event as they become available.

• Persico S.p.A and Rotoline were awarded Supplier of the Year.

• The Charles D. Frederick Distinguished Service Award was presented to Adam Covington from Ferry Industries.

• Excellence in Member Recruitment to Entec Polymers and Ferry Industries.

• Safety Awards were presented to Formed Plastics and Flexahopper Plastics.

• Student Design Awards were given to Jesslyn Gudeman, Bronte Kunkler, and Sofia Solano Brenes of Purdue University.

• Product of the Year and Large Product Award were awarded to Hedstrom Plastics for the Float/Boom, used for spillway protection, debris mitigation, and dam safety.

• The PVC Product Award was presented to Hedstrom Plastics for the WeckMethod RMT Club, a functional training tool used to improve power, mobility, balance, and coordination.

• Previously announced: Rick Carlsen and Dave Smith were inducted into the Rotational Molding Hall of Fame R

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ARM REPORT

Rotoplas 2026: Let the Good Times Roll in New Orleans Rotoplas, the world’s largest rotomolding exhibition, returns to New Orleans November 16 to 19, 2026, as part of ARM’s 50th Anniversary. The event will take place at the National WWII Museum, the New Orleans Convention Center, and Mardi Gras World. More details are available at Rotoplas.org.

Booth sales had been open for less than a week at press time, and more than 25 companies had already reserved space.

Rotoplas 2026 will feature two keynote speakers.

Aron Ralston, known for his survival in a remote Utah canyon and for the film 127 Hours, will tell the story of the six days he spent trapped and how he freed himself and recovered. His talk encourages audiences

to face hard situations with purpose and to find strength in their relationships and resolve.

Alex Chausovsky will open the program with “What to Expect in 2027 and Beyond.” He will explain how recent laws and new tariffs may shape the economy, and what trends in spending, investment, labor, inflation, and interest rates mean for business planning. His goal is to give leaders practical guidance for making decisions in uncertain conditions.

Rotoplas brings together manufacturers, suppliers, designers, engineers, and researchers to explore new ideas in rotational molding. Attendees will see what is driving the industry and shaping its future as ARM marks fifty years in New Orleans. R

Upcoming Winter Webinars and On-Demand Training This winter, ARM members have access to new webinars that focus on technology, safety, and sales skills. Each program is free with your membership and will be available on demand afterward, alongside more than one hundred other training

slowing or stalling. You will learn how to create urgency, manage each stage of the sales cycle, and overcome the delays that lead to lost business.

ARM and Sandler Webinar Series: A Reliable, Transferable System for Selling

Adam Covington of Ferry Industries will provide a clear overview of the safety systems used in rotomolding operations. He will discuss guarding and enclosures, safety circuits, oven controls, temperature monitoring, PPE, emergency procedures, lifting systems, ergonomics, work-zone protection, signage, and fire safety. The session focuses on practical steps molders and suppliers can take to reduce risk and support safer, more reliable production.

ARM is partnering with Sandler to offer a three-part sales training series. These sessions are designed to help you build stronger pipelines, lead more effective teams, and keep deals moving.

Prospecting: Filling the Funnel – January 21

This session covers the core prospecting habits that lead to steady growth. You will learn how to bring more qualified opportunities into your funnel and keep a consistent rhythm that supports long-term success.

Sales Manager Essentials – February 18

This program is designed for sales leaders. It focuses on the practices and metrics that define effective sales management and shows how to coach teams toward higher performance.

Creating Urgency and Keeping Deals Moving – March 11 This session explains how to prevent deals from

56 ROTOWORLD® ISSUE 4 • 2025

Rotomolding Machine Safety Systems – January 29 at 10 a.m. Central

All webinars will be added to our on-demand library after their live dates, giving members flexible access throughout the year.

Has your team tried the ARM Training Academy?

Boost your team’s rotomolding skills with the Operator Training, Wall Thickness, XLPE Series, and Health & Safety Programs (available in Spanish and English). Includes videos, quizzes, and a certificate of completion. The program is free for all employees of ARM member companies. R

ARM REPORT

The Benefits of Membership Train your employees, reduce scrap, connect with customers, learn from experts and peers.

This is what comes with membership and the return on your investment is tremendous.

Complimentary Registration for the 2025 Annual Meeting

Provided for one employee for each new member company. This is your free entry to the world’s largest rotomolding meeting of the year.

Sample Operator Instructions

An 80+ page document calling out the highlights of nine company’s operator instructions. Also more than 700 documents and presentations from past Annual Meetings.

Immediate Free Access to more than 125+ on-demand webinars

Topics range from Determining Your True Cost to Proper Sampling Techniques. We offer four online certificate programs available to your entire team.

Immediate Free Access to ARM’s classic training video library

Includes programs on curing, venting, and good manufacturing practices. All videos include Spanish subtitles.

Free Access to Troubleshooting Calls

These moderated teleconferences are conducted every six weeks (eight per year) and allow you to troubleshoot your process and discuss HR issues with other molders, suppliers, and rotomolding experts.

Rotolink

Our twice weekly e-newsletter shares important industry news.

Annual Meeting

The premier event for rotomolders, their suppliers, designers, and educators. Programming includes professional and industry speakers, valuable networking, group workshops, and exhibition. R

Networking with Industry Peers

The greatest ARM benefit: Informal learning at a coffee break could revolutionize your process or reduce your expenses by tens of thousands of dollars.

We hear it from members again and again.

Awards and Awareness

Showcase your company in our online member directory and through awards including Safety Award, Product Competition, and more.

To apply for membership, please visit www.rotomolding.org www.rotoworldmag.com 57

ARM

ANNUAL MEETING

Industry Visionaries and Technical Leaders Converge in Dallas SUSAN GIBSON, JSJ PRODUCTIONS, INC.

The Association of Rotational Molders (ARM) welcomed more than 375 rotomolders, suppliers, and other professionals from around the world to the 2025 ARM Annual Meeting, held in late September at the Hilton Anatole in Dallas, Texas. The event delivered a comprehensive program of leadership insight, technical education, and forward-looking innovation for the rotational molding industry.

The conference opened with a compelling keynote address by former U.S. Navy SEAL and author Robert O’Neill, who served from 1996 to 2012 and is widely recognized for his role in the 2011 operation that killed

58 ROTOWORLD® ISSUE 4 • 2025

Osama bin Laden. A former member of SEAL Team 6, O’Neill drew powerful parallels between combat leadership and business management. Emphasizing decision-making under pressure, he noted, “To be part of big change, you have to take emotion out of the decision-making process.”

O’Neill stressed the importance of composure, adding, “If one person gets scared, everyone gets scared.

If your people see calm, they will feel calm.”

Educational sessions throughout the meeting addressed current challenges and emerging opportunities across the industry.

Matthew Jeffries discussed real-time machine monitoring,

highlighting the Rotoline Dashboard—provided free to customers—as a tool for achieving production visibility, improved productivity, and consistent quality.

Jeffries also introduced Roto API 4.0, a paid application offering expanded functionality as a more comprehensive monitoring solution.

Professor Denis Rodrigue of the Department of Chemical Engineering at Université Laval (Quebec, Canada) presented an update on the Crawford Education and Development Foundation– funded project, Introduction of Recycled Crosslinked Materials in New Parts. The research focuses on crosslinking virgin and recycled polyethylene (PCR), de-crosslinking

Jerico Plastic Industries Booth

Hall of Fame inductee Rick Carlsen and family

Jay Reid and Ana Lisa Allen

Hall of Fame Inductee Dave Smith and family

Alvin Spence and Claudia Persico

Austin Miller

Matthew Jeffries

Evan Silo

foamed PE, PE composites (WPC), and other materials including PP and PA. Rodrigue emphasized that while recycled materials can be used in rotomolding, careful process control is required.

Ongoing developments aim to improve material quality and sustainability, though additional work is needed to optimize recycling conditions.

Lanhe Zhang of Dow Chemical followed with a presentation on improving PCR performance for rotomolding applications. Zhang detailed Dow’s PCR-containing concentrate—comprised of 70% PCR and 30% virgin resin booster— designed to deliver consistent quality and reliability. Zhang recommended the use of PCR Enhancer as a toughening agent and compatibilizer to support the creation of 100% PCR blends.

Dr. Nick Henwood, ARM Technical Director, provided an update on the ARM Test Method for Low Temperature Impact Testing.

Originally developed under ASTM D1995, the method has become an unofficial industry standard.

Four volunteer laboratories contributed to parameter development and validation, with publication of results targeted for December 2025.

Adam Covington of Ferry Industries presented on datadriven decision-making using real-time monitoring systems. His session covered trend analysis, historian logging, digital chart recording, and preventative maintenance strategies, emphasizing the importance of networking capabilities and actionable data for operational efficiency.

Dr. Paul Nugent of Polymer Link discussed “Closing the Loop on Rotomolded Crosslink.” Founded 60 ROTOWORLD® ISSUE 4 • 2025

Tony Short, Adam Covington, and Alvin Spence

Keynote Robert O’Neill

Alvin Spence gets a chuckle

in 2014 and headquartered in Kuala Lumpur, Polymer Link operates globally and holds multiple international certifications. Nugent outlined the company’s advanced production capabilities, R&D resources, and broad product portfolio, including recycled grades with PCR content ranging from 30% to 80%. He summarized the circular process succinctly: “You mold it, sell the good, gather the bad, chip it, ship it, reformulate it, and start over again.”

A collaborative presentation by Bill Spencely of Flexahopper and Dave Sullivan of NOVA Chemicals demonstrated how combining electric heating technology with NOVAPOL® TRx resins can significantly reduce cycle times

and energy consumption. The study reported up to 30% savings in both energy use and cycle time for thickwalled tanks.

Additional technical sessions included ExxonMobil’s Ziaodan Zhang, PhD, on troubleshooting field failures in rotationally molded polyethylene parts, and Gareth McDowell of 493K Limited on automating cooling rates to improve part consistency and cycle time control. Przemyslaw Orlik of OREX compared gas-powered and electric carousel machines, highlighting differences in energy consumption and production costs.

Jon Smalley of RotoEdge Pro addressed the growing role of artificial intelligence in manufacturing. He emphasized

Ken Bather

ARM Trade Show

Clark Boyce

Paul Nugent

Bradley Roberson

Jerico After Party

Marc Blosser

Jon Smalley

Brandi Frey

AI’s ability to replace spreadsheetheavy decision-making with integrated, real-time insights across production, labor management, scheduling, and financial operations.

Matrix Polymers’ Aldo Quaratino introduced Evolve® Technology, which demonstrated 10–20% reductions in cycle time and energy consumption while maintaining material properties and reducing emissions.

Workshops for the event included: Rotomolding Safety Systems (Adam Covington, Ferry Industries); Women in Rotomolding: Leadership, Challenges, and Community Support (Brandi Frey, Jerico Plastics; Conchita Miranda, Miraplastek; and Chantal Laflamme, Wittman RotoLoad); Cycle Times, Cook Times, and Demold Temps (Dr. Nick Henwood); If It Ain’t PE, It Isn’t for Me (Dr. Nick Henwood); The Future of Automation (Chatal Laflamme, Wittman RotoLoad); The Seven Stages of Rotational Molding (Dr. Gareth McDowell, 493 Limited); Advanced Rotational Molding with Radiant Solar Energy - Site Selection, Productivity Modeling, and Thick-Thin Manufacturing (Ben Presley, Light Manufacturing); What’s Your Problem (Jon Ratzlaff, Chevron Philips Chemical Company and Dru Laws, Brigham Young University, Idaho).

Pre-conference seminars included Roto 101, presented by Dru Laws; Advanced Rotomolding, presented by Dr. Nick Henwood, and Design, presented by Michael Paloian, provided attendees with both foundational and advanced technical knowledge regarding the process.

The ARM Exhibit Hall was full and engaging. It once again proved to be an integral part of the show providing networking, access to the 62 ROTOWORLD® ISSUE 4 • 2025

Daven Claerbout

Conchita Miranda

Paul Nugent

Tony Short sings at the Jerico After Party!

latest in technology and supplies, training, industry insights, and business development ideas.

Thank you to the following ARM Sponsors for making the event a huge success: Brunk, Entec, ExxonMobil, Ferry Industries, Jerico Plastic Industries, Lyondell Basell, M Holland, McCann Plastics, Mosaic Roto, Muehlstein, Nexeo Plastics, NOVA Chemicals, Quantum, Rotaloc, STP Rotomachinery Group, Stoner Molding Solutions, and Wittmann RotoLoad.

From insightful leadership perspectives to collaborative technical advancements, the 2025 ARM Annual Meeting delivered exceptional value to attendees.

The industry now looks ahead to the 2026 ARM Executive Forum, scheduled for June 8–12, 2026, in Belfast, Northern Ireland.

Further details are available at rotomolding.org. R

2025 ARM Awards

The ARM Gala recognized outstanding contributions across the industry. Persico S.p.A. and Rotoline received Supplier of the Year honors, while the Charles D. Frederick Distinguished Service Award was presented to Adam Covington of Ferry Industries.

Additional awards recognized excellence in member recruitment, safety, student design, and product innovation. The ARM Hall of Fame induction—the organization’s highest honor—was awarded to Rick Carlsen and Dave Smith (watch for an article on these Hall of Fame winners in the next issue of RotoWorld®).

NOVA Chemicals Booth

Nicholas Vegas Dias and crew from Venezuela along with Jose Gomez

Jim Crawshaw and PSI Brand Booth

Jim Hummel and Powder King booth

Pat Long

Orla Nugent, Brenda Smith, Jennifer Gibson-Hebert, and Susan Cunningham

Jon Hand

Ben Pressley

Adam Goff

ROTO AROUND THE WORLD

IAN HANSEN RotaConsult

TAIWAN - ROTOMOULDING PIONEER - TA FONG PLASTIC Taiwan may be modest in scale, an island about the size of U.S. state Maryland, but it is home to around 23.5 million people.

Taiwan is one of the most densely populated places in the world.

Most of its citizens live in bustling cities such as Taipei, Taichung, and Kaohsiung, where industry, commerce, and culture converge.

Taiwan is a place where land is limited, but opportunity is boundless. Over the decades, this island nation has become globally recognised as a hub of technology, manufacturing, and innovation, contributing far beyond its physical scale.

From Agriculture to High-Tech Powerhouse

Since the 1970s, Taiwan has undergone a remarkable transformation. What was once a largely agricultural economy has modernised into one of the world’s most advanced manufacturing and technology centres. This rise was driven not only by domestic ambition but also by global influence, as foreign investment, technology transfer, and access to international markets enabled Taiwan to evolve from basic manufacturing into electronics, plastics, and precision engineering.

Yet it wasn’t just capital and technology that made the difference — it was people.

Taiwan’s workforce, known for its discipline, adaptability, and technical skill, became the backbone of its industrial success. Coupled with strong investment in education, a culture of hard work, and a spirit of entrepreneurship, Taiwan built an economy where innovation thrives. By 2025, the island stands as a shining example of how global partnerships, local resilience, and cultural determination can secure a place at the forefront of world markets.

Figure 1

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ROTO AROUND THE WORLD

The Rise of Taiwan’s Rotational Moulding Industry As part of this industrial evolution, Taiwan also became an early adopter of plastic rotational moulding, a sector that has grown steadily since the late 1960s. Initially focused on water storage and utility products, the industry has expanded into automotive, logistics, outdoor leisure, and infrastructure solutions, reflecting the country’s ability to align traditional manufacturing with advanced industrial needs. Taiwan’s rotational moulding sector is characterised by its focus on precision, durability, and exportquality standards, mirroring the nation’s broader reputation for reliability in manufacturing.

Ta Fong Plastic Co., Ltd.: Pioneers of Rotational Moulding

Within this broader story of modernisation, Ta Fong Plastic Co., Ltd. (Ta Fong) holds a special

Figure 3: Fusion welded nozzles in tank roofs

place. Founded in 1968, Ta Fong commissioned one of Taiwan’s first rotational moulding plants and remains one of the country’s leading plastic manufacturing experts. With capabilities spanning rotational moulding, extrusion moulding, and thermoforming, the company offers end-to-end solutions from design and tooling to full-scale production.

Ta Fong is located near Taichung, in central-western Taiwan, known for its cultural

heritage and natural scenery, including the landmark Great Buddha Statue of Baguashan.

About 180km or 2.5hrs drive south of the capital of Taipei.

Unlike many rotomoulders focused on consumer or agricultural products, Ta Fong carved a distinct niche in industrial-grade applications, becoming renowned for chemical and water tanks, automotive components, drainage pipe, and infrastructure products.

Through rigorous quality control and technical expertise, the company has successfully positioned itself as a trusted supplier across Asia, exporting into high-standard industrial supply chains.

Shaping the Future Through Specialisation

Figure 2: Early agricultural rotomoulded products

The strength of Ta Fong lies in its commitment to reliability and innovation. By focusing on high-quality industrial storage tank solutions rather than massmarket water tanks, the company demonstrates the value of strategic focus in a competitive global environment. Every industrial tank sold is customised with different quantity and sizes

www.rotoworldmag.com 65

ROTO AROUND THE WORLD

with an access Ta Fong also manufacture platform on top of the standard water storage tanks tank and an access up to 30,000L (7,925USG), cone ladder. The sheet bottom tanks up to 12,000L metal bands support (3170USG), sloped bottom vertical these external loads tanks up to 25,000L (6,600USG) which are additional and transport tanks up to 5000L to the hydrostatic (1320USG). load.

For tanks holding Moulding the future with liquids with specific speciality equipment gravity higher than Ta Fong began their rotomoulding 1.0 the sheet metal journey in 1968 using open also helps manage flame rock and roll machines the increased liquid manufactured in-house to make weight and increased small open top tanks up to 1200L, hydrostatic load on mainly for agricultural of fishing Figure 4: 50,000L with sheet metal bands, roof safety rail & access ladder the polyethylene tank. applications. Ta Fong were The sheet metal helps introduced to rotational moulding minimise the tank PE technology from Suiko Co., Ltd wall thickness, which in Japan after the company of flange or nozzle inlets and also minimises the moulding cycle chairman interned at Suiko Co. outlets or internal pipework. time, as well as polyethylene While rock & roll machines This approach reflects Taiwan’s weight and material cost. are still used to mould large broader industrial evolution— from small-scale manufacturing to world-class leadership in advanced, precision-driven industries.

Ta Fong manufacture and market Ultra Large (UL) industrial tanks, with liquid capacities up to 50,000Litres (13,200USG). The largest tank has diameter of 3.1m and a height of 7.4m (122” x 291”).

These are extremely tall tanks and consequently exert extremely high hydrostatic loads. To help manage the side wall stress and reduce the PE (polyethylene) wall thickness requirements, most tanks are moulded with a triple layer foam sandwich system.

Solid outer coloured layer, foamed middle layer, and solid inner natural layer.

UL and other large tanks Figure 5: 50,000L industrial tanks and 30,000L dedicated can be supplied with external fire fighting tank – local regulations require these to be red metal band supports. These are required when tanks are supplied

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ROTO AROUND THE WORLD

tanks, biaxial hot air ovens were introduced in 1995 with the commissioning of a Ferry Express E100 shuttle. In more recent years they have commissioned shuttle machines from Rising Sun. The biaxial ovens allow better thickness control for more complex mould shapes; like their 4200L (1100USG) underground tank.

Ta Fong manufacture their own powder in-house. Their 3rd set of Reduction Engineering pulverisers was installed in 2015.

Their colours are dry blended, which is one of the primary reasons why they use natural PE for the inner layer of their tanks – to ensure no contamination (pigment migration) is possible to the liquids stored within the tanks.

Ta Fong source their PE rotomoulding raw materials

Figure 6: Open Flame Rock & Roll machine with 25,000L rectangular mould

locally from Formosa Plastics and import from South East Asia.

Formosa will be well known to North American moulders as they have extensive petrochemical and plastic facilities in the US. Unlike the US, Taiwan only has one rotomoulding grade available

which is why Ta Fong also import rotomoulding material.

Sustainability

Ta Fong have adopted a longterm sustainability program by installing solar panels on its factory roof able to generate

Figure 7: Ta Fong factory, 11,550sqm (124.000sqft), during installation of 1300 solar panels capable of up to 490kWp power generation

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ROTO AROUND THE WORLD

Figure 8: Biaxial shuttle machines are used because they take up less factory floor space (than comparable carousel machines)

up to 490kWp of power. This compares to Flexahopper (Canada) 167kWp, Pentas Moulding (Netherlands) 500kWp, Baroda Polyform (India) 575kWp, and Fuji Pipes (Philippines) 1,500kWp. For Ta Fong solar panels had the additional benefit of reducing heat inside the factory because the sheet metal roofing allowed easy heat transfer into the factory. Ta Fong have also installed a negative air pressure system in the factory to help manage the hot temperatures.

Taiwanese summers are typically 27–35°C (81–95°F) with high humidity. This system uses air ducting and fans throughout the factory pulling hot air out through the roof. This program is an example of a company’s commitment to energy efficiency and long-term operational resilience.

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Rototour: Taiwan on the Global Stage

Ta Fongs’ global reputation was highlighted during the 2025 ARMA Rototour, which brought

together rotational moulding manufacturers, suppliers, and technical experts to promote technical exchange and international collaboration.

This year, 33 representatives from 11 countries (Australia, Brazil, China, Canada, Kazakhstan, Malaysia, Morocco, the Netherlands, Philippines, UK and USA) visited Ta Fong’s factory.

The factory tour at Ta Fong was hosted by Chief Operating Officer Kevin Tseng and General Manager Vincent Tseng, underlining the company’s role not only as a domestic leader but also as a global partner in shaping the future of rotational moulding. (Note: Rototour also visited Suiko Co in Japan)

Innovation in Action: Hot-Melt Pipe Technology One of the highlights for the Rototour team was Ta Fongs’ exclusive electronic hot-melt

Figure 9: Kevin Tseng explaining to Rototour how they use fusion welding techniques to fit stub flanges or pipes into tank walls

ROTO AROUND THE WORLD

technology. This process enables a PE stub flange inlet or outlet to be directly fusion welded to the tank body, creating a seamless, one-piece moulding effect.

While similar to existing socket fusion welding technology, it is modified to suit Ta Fongs’ fabrication requirements. By eliminating the risks of leaks associated with traditional manual welding (fillet welding around the external tank wall and stub flange) this hot melt process can improve product quality and durability.

The welding technology’s impact has gone beyond recognition - it has earned Ta Fong the status of designated supplier of industrial-

grade PE storage tanks for TSMC, (Taiwan Semiconductor Manufacturing Company) Taiwan’s most prestigious global technology company. This endorsement is a testament to Ta Fongs’ reliability and technical expertise, showing how rotational moulding innovation can support technology industries where quality and performance are nonnegotiable.

A Country of Scale and Impact

infrastructure and automotive markets, the nation has built a reputation for quality, resilience, and innovation.

Companies like Ta Fong Plastic are not only ambassadors of this Taiwanese industrial spirit but also pioneers in executing the rotomoulding process well, reminding us that rotational moulding offers the possibility to make almost anything you can imagine wherever in the world you are. R

Though small in size, Taiwan has consistently proven its ability to achieve outsized impact. From the semiconductor industry powering global technology to the plastics industry supplying critical

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ARMO NEWS

ARMA | ARM-CE | ARMSA | BPF | IT-RO | NORDIC ARM | StAR

Rotomould 2026 Melbourne | Save the Date We’re excited to announce that ARMA’s Rotomould26 Conference & Trade Exhibition is officially locked in for Monday, 22 June to Wednesday, 24 June 2026 at the stunning Langham Hotel on Melbourne’s Southbank!

Melbourne is a city that captures the heart and imagination of every visitor with its blend of cosmopolitan flair, cultural diversity, and cutting-

edge style.

Stroll through the laneways adorned with vibrant street art, sip coffee at one of the world’s best cafés, explore iconic cultural institutions, or unwind by the Yarra River as the city buzzes around you. Whether you’re discovering world-class restaurants, quirky boutiques, or rooftop bars with unbeatable views, Melbourne offers a dynamic backdrop for your conference experience. R

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ARMO NEWS

Want to Share Your Expertise?

We’re on the lookout for Presenters, Panellists, and Program Contributors who want to bring fresh ideas to the stage. Whether you’ve got a groundbreaking case study, innovative approach, or a compelling personal journey to share, we’d love to hear from you. You can choose from a 30-minute presentation,

panel discussion, or even an interview-style session.

Not confident about public speaking? Don’t worry, we have presentation formats designed to help you share your story without the stress. If you’ve always wanted to share your experience but felt hesitant, now’s your chance. R

Showcase Your Work For rotational moulders, this is your moment to shine.

Submit your case study for a chance to be part of the

event, and if selected, you’ll receive a complimentary conference registration! R

Sponsorship & Exhibition Opportunities Sponsoring & exhibiting at Rotomould26 is a fantastic way to build new relationships and strengthen existing ones while showing your support for the rotational moulding industry. It’s the perfect platform to elevate your brand and connect with key players in the field.

For more information, feel free to reach out to us at events@rotationalmoulding.com. We can’t wait to see you there! R

Student Design Awards ARMA is committed to connecting design and engineering students with real industry opportunities and that’s why we’re excited to launch the 2026 Student Design Awards.

We’re inviting universities across Australasia to get involved by incorporating the competition into their Term 1, 2026 curriculum. It’s a chance for students to take on a genuine manufacturing challenge using rotational moulding and explore what’s possible with this versatile process. Universities can embed it into coursework or simply share the opportunity with students and colleagues.

2026 Theme: Design for Inclusion Key Dates: Entries open January 2026 · Entries close 8 May 2026 Prize Pool: $5,000 Winners Announced: At ARMA’s Rotomould26 conference in Melbourne (22–24 June 2026) This program offers students industry-relevant experience, exposure to manufacturers, and optional add-ons such as guest lectures or factory tours to deepen learning.

To participate or learn more, contact ARMA at info@rotationalmoulding.com. R

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ARMO NEWS

Star Annouces Annual Rotomoulding Conference In Delhi, India – February 2-4, 2026 Sudeep Sarkar, Executive Director, StAR

OVER 100 DELEGATES • 20 TRADE SHOW BOOTHS • 20 NATIONAL & INTERNATIONAL SPEAKERS

The Society of Asian Rotomoulders (StAR) is all set to conduct ‘StAR 2026 Annual Conference and Trade Show’, from February 2-4, 2026, which is designed strategically just before the mega event PlastIndia 2026 (Feb. 5-10, 2026) – the largest Trade Show on Plastics in India held every 3 years.

The dates and the venue for the StAR 2026 Annual Conference and Trade Show is selected to enable attendees (both domestic and International) to participate in PlastIndia 2026 (12th International Plastics Exhibition, Conference & Convention at Bharat Mandapam, Delhi).

Delhi, the heart of Incredible India, perfectly blends history and modernity — an inspiring setting for this prestigious International Conference and Trade Show. The city successfully hosted the ARMO 2025 Conference, which drew over 260 delegates from 30+ countries, including a strong 40% foreign participation

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and the largest delegation from Poland.

Theme

Roto 360: Innovation, Impact & Intelligence Building on India’s dynamic growth story, the Society of Asian Rotomoulders aims to highlight the remarkable transformation of the Indian rotomoulding sector — from water tanks to diversified, value-added products — creating a unique, world-class conference experience.

Schedule of Events FEBRUARY 2, 2026 (Monday) 09:00 AM – 05:00 PM – Full Day Seminar 04:00 PM – 06:00 PM – Trade Show 07:00 PM – 10:00 PM – Networking Reception & Dinner

ARMO NEWS

ARMA | ARM-CE | ARMSA | BPF | IT-RO | NORDIC ARM | StAR

FEBRUARY 3, 2026 (Tuesday) 09:00 AM – 05:00 PM – Full Day Conference Presentations 09:00 AM – 05:00 PM – Trade Show 07:00 PM – 11:00 PM – Reception and Gala Dinner with Entertainment FEBRUARY 4, 2026 (Wednesday) 09:00 AM – 01:00 PM – Conference Presentations End of Programme

More Than Just a Conference

While the conference provides exceptional opportunities for learning, networking, and knowledge exchange, it’s also an event that welcomes spouses and accompanying guests. Delhi offers a vibrant cultural experience — from its monumental heritage to its rich cuisine and colourful traditions — ensuring an unforgettable experience for everyone.

Dedicated Website: www.star2026.org

StAR has launched a dedicated event website, serving as a one-stop portal for all conference-related information viz. Speakers Programme, Seminar, Sponsorship, Trade Show Participation, Delegate Registration, Hotel Booking and Transportation Assistance.

Stay tuned for regular updates and announcements as StAR 2026 shapes up to become the significant rotomoulding gathering ever hosted in India! R

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ARMO NEWS

ARMA | ARM-CE | ARMSA | BPF | IT-RO | NORDIC ARM | StAR

Plastics Federation calls for urgent government support for UK plastic recyclers The British Plastics Federation (BPF) has warned that the UK is at serious risk of losing its domestic plastic recycling industry. Over the past two years, more than 17 UK plastic recycling sites or companies, with a combined processing capacity of roughly 400,000 tonnes, are no longer operational. This decline not only undermines the UK’s ability to manage its own plastic waste but affects hundreds of jobs.

Philip Law, Director General of the BPF, said: “The government is quite rightly focused on developing a circular economy for the UK, but this will be unachievable without a strong UK plastic recycling industry, an industry that is currently being eroded.

There has been a neglect of support for UK plastic recycling companies as individual businesses in recent years. The UK government targets for plastics recycling have only been met due to the export of waste supported by the Packaging Export Recovery Notes (PERNs) rather than encouraging domestic recycling in the UK with all the investment and jobs that this would create.”

He added: “The industry urgently needs the government to take action to support the remaining companies otherwise it risks yet more degradation of our domestic recycling capability and becoming entirely reliant on an export-based waste management model.”

The BPF’s “Stabilise & Grow” plan outlines how to tackle what the BPF are describing as a “perfect storm” for plastic recyclers. This is driven by: • High domestic manufacturing costs – including energy, labour and compliance with stringent regulatory standards • Cheap imports of recycled plastics from low-cost economies outside the EU, where reprocessing costs are significantly lower and regulatory demands more relaxed • Low-cost imports of virgin plastic exacerbated by expanding raw material production in Asia and the USA • Exports of plastics waste incentivised via PERNs which provide a cheap route for recycling but make tracking where and how recyclate is used challenging.

• Fraudulent claims about the recycled material content within packs have been made. Member firms have understandably been uncomfortable in

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reporting such incidents.

• Long delays in legislation and regulatory reform, causing uncertainty that deters investors and hampers long-term planning The result has been a shrinking domestic recycling sector at the very moment when the UK must deliver on circular-economy ambitions.

Philip Law concluded that: “Whilst the government is beginning to recognise the situation and respond there has still been no immediate action. We urge the government to look to initially stabilise and then grow the industry.”

What needs to happen now — immediate and longterm action The BPF’s “Stabilise & Grow” plan sets out a twopronged strategy to first secure the remaining sector, then rebuild growth.

STABILISE – immediate actions to secure the sector

• Energy relief: Provide targeted energy rebates or support for UK plastic recyclers and make them eligible for the Climate Change Agreement (CCA).

• Deliver PRN/PERN reform: Increase transparency by disclosing tonnages of individual reprocessors/ exporters, strengthen enforcement to tackle waste crime/fraud, and revoke fraudulently issued certificates. Level the playing field between domestic reprocessors and exporters.

• Reinvesting in the sector: Use revenue from the Plastic Packaging Tax (PPT) to support domestic recycling infrastructure (or fund relevant government departments tackling waste-crime or supporting recycling).

• Certification for recycled content under PPT: Require certification of recycled content used towards the PPT, ensuring that both domestic recyclers and importers meet the same standard.

• Alignment with the EU: Ensure future alignment to support trade and competitiveness where it is relevant.

Acceptance of UK material within the Packaging and Packaging Waste Regulations (PPWR) under Mirror Clause 7

ARMO NEWS

ARMA | ARM-CE | ARMSA | BPF | IT-RO | NORDIC ARM | StAR

• Safeguards for end markets: Enable anti-dumping duty where appropriate and use legislation to promote the use of UK recycled material • SMEs permit support: Continuation and increased flexibility of the current exemptions for plastic reprocessors

GROW – strategic measures for long-term confidence and capacity

ASSOCIATION OF ROTATIONAL MOULDERS AUSTRALASIA LTD Michelle Rose, CAE Chief Executive Officer

• Drive demand for UK recyclate: Government procurement policy and regulation should favour products made with UK-processed recycled plastic. Legislation should encourage the plastic supply chain to source domestically recycled content. Expand legislation to other sectors such as Extended Producer Responsibility (EPR) to encourage collection and demand • Retain material within the UK: Use relevant legislation (PRN/PERN scheme, Deposit Return Schemes or other schemes) to prioritise UK reprocessors - reduce export of waste plastic and build domestic circularity.

• Fast-track environmental permits: Streamline permitting and planning for new or expanded recycling infrastructure. For instance, update frameworks (e.g. the National Planning Policy Framework) to enable faster decision-making and reduce investment delays.

• Legislate for Design for Recyclability (DfR): The Government must legislate for Design for Recyclability (DfR) across all sectors and require producers to manufacture products that are easily recycled

PO Box 237 Moonee Ponds VIC 3039 Australia

Why this matters beyond the recycling industry

Phone: +039 348 7652560 www.it-ro.it

The BPF argues that beyond industry health, a robust UK recycling sector underpins the nation’s broader circular-economy and net zero ambitions, delivering environmental benefits, lowering carbon emissions, and creating jobs across collection, processing, manufacturing.

Failure to act risks not only further closures and job losses but also undermines the credibility of the UK’s sustainability commitments.

The BPF calls on government to adopt the “Stabilise & Grow” action plan without delay to secure existing capacity, restore investor confidence, and build a resilient UK plasticsrecycling sector essential for a truly circular economy. R

Phone: + 61 (0) 404 265 887 michellerose@ rotationalmoulding.com www.rotationalmoulding.com

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 Phone: +27 82 772 3769 Fax: +27 12 541 1738 Chairman: Gary Wiid info@armsa.co.za www.armsa.co.za

BRITISH PLASTICS FEDERATION ROTATIONAL MOULDING GROUP 6 Bath Place Rivington Street London EC2A 3JE United Kingdom 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

THE NORDIC ASSOCIATION OF ROTATIONAL MOULDERS Executive Board Chairman: Mr. Ronny Ervik ul. Zielona 8, 61-851 Poznań, Poland

SOCIETY OF ASIAN ROTOMOULDERS (StAR) 40/145, Ground Floor, Chittaranjan Park New Delhi 110019

Phone: +48 607-126-004 Fax: +48 61-858-8611 info@rotomoulding-europe.org www.nordicarm.org

Phone: + 91-11-41630157 Fax: +91-11-41634952 Cell: + 91- 9810305356 2sudeepsarkar@gmail.com arnacz@satyam.net.in www.starasia.org

www.rotoworldmag.com 75

G LO B A L C A L E N D A R

JAN

26-28 2026

NORDIC ARM CONFERENCE Radisson Blu, Stockhom Airport Stockholm Sweden nordicarm.org

MAR

6-9 2026

ANTEC

Sheraton Philadelphia Downtown Pittsburg, PA antec.com

76 ROTOWORLD® ISSUE 4 • 2025

FEB

2-4 2026

2026 ANNUAL ROTOMOULDING CONFERENCE & TRADE SHOW Raddisson Blu Towers Kaushambi Delhi NCR

JUN

8-12 2026

ARM EXECUTIVE FORUM Belfast, Northern Ireland rotomolding.org

G LO B A L C A L E N D A R

JUN

22-24 2026

ROTOMOULD26 CONFERENCE & EXHIBITION Melbourne, Australia

NOV

16-19 2026

ROTOPLAS 2026 & ARM 50TH ANNIVERSARY MEETING Ernest N. Morial Convention Center New Orleans, LA rotomolding.org

1-2 2026

JUL

BPF NETWORKING DAY Nottingham, England www.bpf.co.uk

3-7 2027

MAY

NPE 2027

Orange County Convention Center Orlando, FL npe.org

www.rotoworldmag.com 77

ADVERTISERS’ INDEX

45 Diversified Mold & Castings 19800 Miles Road Warrensville Hts., OH 44128-4118 USA 216.663.1814 | 888.642.1222 info@diversifiedmolds.com www.diversifiedmolds.com 5 Ferry Industries, Inc. 4445 Allen Road Stow, OH 44224-1093 USA 330.920.9200 sales@ferryindustries.com www.ferryindustries.com 9, 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 69 Poliplast S.p.A. Via Carrali, 8 24020 Casnigo (BG) Italy +39.035.724145 info@poliplastspa.com www.poliplastspa.com

78 ROTOWORLD® ISSUE 4 • 2025

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 17 Rotaconsult Sydney Australia +61.420.903.039 ianhansenconsult@gmail.com www.ianhansenconsult.com 53 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 19 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 15 Xcelerant Growth Partners 624 W. Washington Avenue, #411 Madison, WI 53703 440.384.7654 info@xcelerantgrowthpartners.com xcelerantgrowthpartners.com

625 West Market Street Salinas, CA 93901 USA

PRIORITY MAIL INTERNATIONAL U.S. POSTAGE PAID AUSTIN, TX PERMIT NO. 2515

VOLUME XXI , ISSUE 4 • 2025

PARDON THE INTRUSION

ROTOWORLD

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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

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Your Premier Compounder and Distribution Partner for Rotational Molding in North America Proudly Supporting the Association of Rotational Molders!

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