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Rotomoulding

About Rotomoulding

What is Rotational Moulding ?

Rotational moulding process is a very simple process for manufacturing hollow, seamless products of all sizes and shapes. Due to its simple operation and relatively low cost moulds, this process has become very popular for manufacturing hollow items like water storage tanks.

Rotational moulding is a Four- Stage process.

Stage 1
Polymer powder is loaded in the mould manually and mould is closed.

Stage 2
The mould is then shifted to the heating oven. Here the mould is heated by forced hot air circulation. While the mould is heated it is also rotate about two perpendicular axes simultaneously. The polymer melts and forms a homogenous layer inside the mould.

Stage 3
The mould is shifted to a cooling station where forced air cools the mould.

Stage 4
The mould is open and finished part is taken out. Unlike injection and blow moulding, rotational moulding does not involve high pressures, hence the products are stress free and have uniform wall thickness. Accurate control of process is very important for producing quality products in rotational moulding.

What is Rotational Moulding ?

Rotational moulding process is a very simple process for manufacturing hollow, seamless products of all sizes and shapes. Due to its simple operation and relatively low cost moulds, this process has become very popular for manufacturing hollow items like water storage tanks.

Rotational moulding is a Four- Stage process.

Stage 1
Polymer powder is loaded in the mould manually and mould is closed.

Stage 2
The mould is then shifted to the heating oven. Here the mould is heated by forced hot air circulation. While the mould is heated it is also rotate about two perpendicular axes simultaneously. The polymer melts and forms a homogenous layer inside the mould.

Stage 3
The mould is shifted to a cooling station where forced air cools the mould.

Stage 4
The mould is open and finished part is taken out. Unlike injection and blow moulding, rotational moulding does not involve high pressures, hence the products are stress free and have uniform wall thickness. Accurate control of process is very important for producing quality products in rotational moulding.

Rotomoulding

Rotomoulding Process Flowchart

  • Step 1: Natural LLDPE granules (from suppliers like Reliance, IOCL,OPAL, Haldia, etc.) mixed with Masterbatch as required.
  • Step 2: This mix of Natural LLDPE granules and masterbatch is fed into the extruder.
  • Step 3: Extruder Extrudes out the polymer in thread form
  • Step 4: The polymer in thread form is fed into the cuts the polymer threads to form colored granules.
  • Step 5: These colored granules are fed into the Pulveriser to get LLDPE powdered form as output.
  • Step 6: The LLDPE powder is charged into the mould for the four stage Rotomoulding process (charge, heat, cool, demould) to begin.
  • Step 7: Rotomoulded Product is ready for finishing and packaging operations to be performed.

Raw Materials

Rotomoulding
Rotomoulding

To obtain the desired end product, the choice of a quality powdered resin is essential in rotational molding. LLDPE (Li near Low Density Polyethylene) in its powdered form is most widely used raw material in Rotational moulding.

LLDPE Powder is generally recommended for:

  • Overhead water tanks
  • Storage bins
  • Toys and traffic barriers
  • Sanitation & Agriculture products
  • Rotomoulding applications requiring outdoor exposure

In- house storage care:Bags should be stored in dry / closed conditions at temperatures below 5o•c and   protected from UV or  direct sunlight.Bags must be kept away from the furnace or any other imflamable objects.

Foaming in Rotational Moulding. PE foam increases rigidity and stiffness of rotational moulded parts while minimising weight. Insulating properties of foam may also have useful applications. Rotational Moulding with PE foam is very simple if machine is equipped with proper process controls. “Vinodrai” machines are highly suitable for making foam products and insulated water tanks.

Advantages of LLDPE Foam Tank.

  • Keeps Water Temperature Normal.
  • Higher Thickness and Rigid Tank.
  • Value added product, better customer preference.
  • Higher realization & better profits.

For other resources such as Powder Suppliers, Plastic Lid Suppliers, Books on Rotomoulding, Rotomoulding  Websites.

Machine Selection

Selection of a rotational moulding machine is based on the following considerations
• Capacity of tank which have max share in market
• Monthly expected production in terms of ltr.
• Range of tanks required in market (Loft, Roof, House hold, Horizontal )
• Running cost of production.

The machine must be selected from the point of view that it should produce the capacity of tank most economically which have max. share in market.

Machine must be able to produce required volume of tanks which are salable in market.

And finally running cost that matters and not capital cost. In the competitive world, running cost of production is the key to survival of a company. The running cost depends upon the selection of the machine. If you selected the machine which is unable to control the fuel, electricity consumption. Employing heavy maintenance and need skilled labor then such machines though are cheap but finely take away the entrepreneur towards the loss.

Therefore machine must be :-

  • Fuel saver
  • Less power consumable
  • Must not be labor oriented
  • Maintenance free and hence interruption free
  • Essay to operate
  • Productive and efficient
Vinodrai

Applications

Rotational moulding is exceptionally versatile process that can produce a huge range of plastic products. Rotomoulded products are used in many key sectors like:

  • Household: Water storage tanks, septic tanks, garden planters, ice boxes and washing stations.
  • Industry: Chemical storage tanks, containers, crates, pallets and insulated fish and cooler boxes.
  • Agriculture: Composters, spray tanks, fertilizer tank, and Tractor attachments.
  • Healthcare: Stretchers, Instrument casings, vaccine boxes, organ storage boxes and cabinets.
  • Military: incendiary bomb casings, missile containers and drop boxes.
  • Environmental: Garbage bins, road cones, road barriers and road signs.
  • Marine: Kayaks, canoes, boats, floats, buoys and pontoons.
  • Automotive: Truck mudguards, ducting, diesel fuel tanks, toolboxes and tractor dashboards.
  • Furniture: Table, Chairs, Luxury LED furniture, study desks, lighting and decorative products.
  • Toys and playground equipment.: Slides, Outdoor gym equipment, amusement and water park equipment.

Process Comparison

Sr No.FactorsRotational MouldingBlow Moulding
1Typical product volume range1,00,000 litres1,000 litres
2Raw material used• Linear Low Density Polyethylene (LLDPE)
• Medium Density Polyethylene (MDPE)
• High Density Polyethylene (HDPE)
• Cross linking Polyethylene (XLPE)
• Polyvinyl Chloride (PVC)
• Polycarbonate
• Nylon
• Polypropylene (PP)
• Several others
• Low Density Polyethylene (LDPE)
• High Density Polyethylene (HDPE)
• Polyethylene Terephthalate (PET)
• Polypropylene (PP)
• Polyvinyl Chloride (PVC)
3Raw material formPowder or LiquidPellets
4Mould materialSteel/AluminiumSteel/Aluminium
5Mold pressureSteel/AluminiumSteel/Aluminium
6Mould costLowHigh
7In-mould graphicsYesYes
8Labour IntensiveMoreLess
9Cycle timeSlowFast
10Wall thicknessUniformity possibleTends to be non-uniform
11Insert feasibilityYesYes
12Residual stressLowHigh

Resources

For other resources such as Powder Suppliers and Plastic Lid Suppliers please click the buttons

Sr.NoName of CompanyAddressContact PersonContact NumberEmail Address
1Phychem Technologies Pvt LtdGut No 172, At post Khatwad Dindori, Nasik. 422002
Maharashtra
Mr Umakant Swadekar+91 9422255035kanadtech@gmail.com
2Ekdant PlasticsPlot no A-112, Five star MIDC Area, Shendra, Aurangabad. 431007
Maharashtra
MR Kishore Rathi+91 9422706700marketingekdant@gmail.com
3Heera Roto PolymerV-21, Additional MIDC, Ajanta Road.Mr. Bhushan Khadake+91 982338424bkhadke@gmail.com
4Petrotech InternationalShed No: A, Sy No: 65/4-A2, 3rd Cross, Ranganathpura, Magadi Rd, Kamkshipalya, Banglore. 560079+91 9448478001, 80- 427743012/3/4All India Associates Branches
5Alok Masterbatches LtdC-65/1, Okhla Industrial Area Phase II, New Delhi. 110 020Mr. Amit SinghPhone : +91 41612244-47
Mobile : +91 9910178122
amitsingh@alokindustries.com
6RotopolymersPlot No. 11, 12, 13, Dholeshawar Ind Estate, Behind Champion Oil Mill, Changodar.
Dist : Ahemdabad
Mr Rashmin +91 9824509797rupasanghvi@yohoo.com
7Calcutta Poly Products IndustriesJessore Road, Kalachandpara Duttapukur, North 24, Parganas. 743248
West Bengal
Mr BS Nandi+91 9830056274suryacppi@gmail.com
8Progressive Roto PlastPlot No:4313/6/7, Road NO 43-D, Near Surat Floor Mill, Sachin GIDC Surat. 394 230
Gujrat
Mr Darshit Parekh & Mr Bharat Padaliya+91 9825111533, +91 9925012699perfectpolymers2005@gmail.com
9Pacific Poly PlastPlot No. 5107,G.I.D.C, Estate, Ankleshwar. 393002
District-Bharuch,
Gujarat
+91 08980960131
10Perfect Roto PolymersShed No. 4313/7,Road No.43-D, Near Surat Floor Mill,GIDC, sachin, Surat. 394230
Gujarat.
Phone : +91-261-6538516/2914644,
Mobile : +91 9953358959
11Riddhi PolymersSurvey No. 736/1, B-4, Ground Floor, Raj Ind Compound, Ringanwada, Daman. 396 210 (UT)Mr Jagdish Thakkar. +91 260 2241154riddhipolyp@sancharnet.in
12Sunrise PolymersD-67, Phave V, Jeedimetla, Hyderbad-500055(+91)- 9849023052sunrisepoly1@gmail.com
Sr.NoName of CompanyAddressContact PersonContact NumberEmail Address
1Yogi Polymer27-28, Nijanand Estate, kunjadiya street,opp,Gupta Mill, Pipodra, GIDC, Surat. 394110
Gujarat
Mukeshbhai Mangroliya+91 9979187722www.yogipolymers.com
2Ornate PolymersParamount commercial complex,3, Rajputpara, Rajkot. 36000
Gujarat
+91 9824507575 / 9824506363www.ornateplastic.com
3Sona plastic UdjogKhasra,No.30, Gram Bhoytawale, Jaipur. 302013Mr. Bhushan KhadakePh : +91 141 3235301
Mob : +91 9953360885
4Manibhadra PolymersC/1B-33 & 34 A, G.I.D.C, Nr. Bank of Baroda, Kabilpore, Navsari. 396445Mukesh KothariPh : +91 2637 327700, 327800
Mob : +91 9427575000
manibhadra.polymers@yahoo.com
5Avani PlastC-65/1, Okhla Industrial Area Phase II, New Delhi. 110 020Mr Jagdish Bhai 9825069528avaniplast@yahoo.co.in
6Sun PolymerSun Polymer+91 9942727888
7Injecto Plast13PN 171-A Zambad Estate, New Shrey, CIDCO, Aurangabad 431001
+91 240 2564266
8Singla Industries176, Block-A, DSIDC Industrial Area, Narela, Delhi.Mr Naresh Singhal+91 9818118854, 9136536625nareshsinghal.a176@gmail.com
9ML IndustriesE-44, Sector 5, DSIDC, Bawana, Delhi 110039Mr. Rakesh Agrawal+91 9350885251, 98310078236ml.industries@yahoo.in

ADDRESS
Head Office & Plant 1:- Vinodrai Engineers Pvt. Ltd. 12 Km Stone, Jalna - Aurangabad Road, Village Dawalwadi, Jalna - 431 203 Maharashtra. India. Dist: Jalna
Plant2:- Vinodrai Engineers Pvt. Ltd. Plot no: B-62 & B-63, 3rd Phase MIDC, Village Nagewadi, Jalna - Aurangabad Road, Jalna - 431 203 Maharashtra. India. Dist: Jalna
Contact Us
Pho: +91 2482 262000Mob: +91 9049113377
vinodraieng@gmail.comdivyaraithatha@vinodrai.com

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