{"id":8619,"date":"2023-12-27T14:15:20","date_gmt":"2023-12-27T13:15:20","guid":{"rendered":"https:\/\/plastipol.pl\/case-study-changing-lamination-technology-to-rotary-casting-technology-to-automate-the-process-reduce-costs-and-increase-aesthetics\/"},"modified":"2024-03-16T13:34:38","modified_gmt":"2024-03-16T12:34:38","slug":"case-study-changing-lamination-technology-to-rotary-casting-technology-to-automate-the-process-reduce-costs-and-increase-aesthetics","status":"publish","type":"post","link":"https:\/\/plastipol.pl\/en\/case-study-changing-lamination-technology-to-rotary-casting-technology-to-automate-the-process-reduce-costs-and-increase-aesthetics\/","title":{"rendered":"Case study: Changing lamination technology to rotary casting technology to automate the process, reduce costs and increase aesthetics."},"content":{"rendered":"\n

Introduction<\/strong><\/h2>\n\n

Plastipol Poland has carried out a successful implementation of mass production of covers and extensions for domestic sewage treatment plants for Eko-Bio. The cover, together with the extension, forms a manhole superstructure to have access from the outside to the inside of the treatment tank. The large dimensions of the product (a 630x330x150 set) meant that implementation into mass production was only possible using rotary casting technology. The premise was to change the time-consuming and unsightly laminating technology to repeatable, accurate Rotomolding<\/a> technology. Thanks to the application of technological knowledge as well as our processing capabilities, manholes can be produced about 300% faster<\/strong> and their unit cost is about 50% lower<\/strong>. The product became much more visually<\/strong> attractive. In addition, the process enabled the use of LDPE material with additives to increase strength. This has made the detail more aesthetically pleasing as well as extending its lifespan<\/strong> by about 260% (to a period of 7 years in outdoor use while maintaining 90% of its properties)<\/strong>, thanks to enhanced UV protection.<\/p>\n\n

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att.1 Set of manhole and cover made by rotary casting technology<\/figcaption><\/figure>\n\n
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att. 2 Sump (cover+over) installed on biological treatment plant Eco-Bio 4000<\/figcaption><\/figure>\n\n

<\/strong>Description of rotary casting and lamination technology<\/strong><\/h2>\n\n

<\/strong>Rotational Molding<\/strong><\/h3>\n\n

Rotary casting<\/a> is one of the modern forms of plastics processing that is gaining popularity. The rotary casting process, also called rotary or centrifugal casting, uses the force of gravity acting on the cast material. The material is introduced into the mold, usually in the form of powder, and then, under the influence of mold heating, it melts in its cavity. The solidification or hardening of the material occurs in the rotating mold, which is then stopped, opened, and the molded product is removed from its cavity.<\/p>\n\n

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Fig.3 Rotational Molding Diagram<\/figcaption><\/figure>\n\n

The characteristic feature of rotary casting, shown in Fig. 1, is to distribute the molten plastic evenly over all the walls of the molding cavity due to the gravitational force from simultaneous rotation around at least two axes. The shape of the mold forming cavity of the rotational casting mold reflects the outer surface of the cast object (in the form of a container), while the inner surface of the casting is shaped freely due to the movement of the material under the influence of gravity. Currently, the industry heavily relies on polyethylene (PE)<\/a>, with 97% of rotationally molded products<\/strong> being made from this material. Polyethylene is a versatile, easily moldable, and readily available polymer that has dominated the process. Rotomoulding is a casting technique where powder is almost always used instead of pellets, which means that the material must be ground.The molds for rotational molding technology are made of steel<\/strong> and aluminum alloys<\/strong>. The production costs of molds vary from 10,000 PLN for smaller details to 60-80,000 PLN for large, complex details with dimensions exceeding 1.5 meters. <\/p>\n\n

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att. 4 \u2013 LDPE powder<\/figcaption><\/figure>\n\n

Advantages:<\/strong><\/p>\n\n