petrol & diesel tanks fresh water tanks grey water tanks ... · custom rotational moulding 5...
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Petrol & diesel tanksFresh water tanks Grey water tanksBlack water tanksOther marine equipment
marineproducts
factories
ROTO is a global producer of high-quality
plastic products from polyethylene,
polypropylene, polyamide, XPE and
ABS with production factories in
four European countries. ROTO is
a family business company that is
presented on the market as a successful
manufacturer and reliable business
partner for more than 40 years.
ROTO is a leading rotational moulder in Europe
with over 4000 different products in range and
size up to 70.000L. These products are exported
in more than 50 countries all over the world.
ROTO performs all stages of the business
process, from product development,
product analysing, own tool production,
prototype manufacturing, serial production,
marketing & sales, distribution and after
– sale service. High quality technical
products are result of latest production
technologies and strong R&D department.
ROTO have the following certifications:• Certification of quality ISO 9001:2008
• Environmental certificate ISO 14001:2004
Custom rotational moulding 3
factoriesA complete IN HOUSE SOLUTION from idea to serial production!
CUSTOM ROTATIONAL MOULDINGYourfrom your IDEA
(sketch, …) mould manufacturing
process
IN AS LITTLE AS 6 WEEKS!
3D modeldesign
first sample production
serial production
With our in-house mould development and production, we ensure that customer sensitive data is only exchanged between customer and our development. Our qualified professional staff are always on-hand to assist.
Throughout the development process we work closely together with our customers providing support with:• Design.• Technical Solutions.• Cost Reduction.
4 Custom rotational moulding
SCOPE OF OUR SERVICES
• 3D model design :• Innovative product development• Computer aided design (CAD)• FEM analyses (to predict and remove critical areas of the products already in design phase)• Failure Mode Effect Analyse• Computer aided manufacturing (CAM)
• Mould manufacturing: • Wide range of conventional, CNC milling machines and CNC lathes• 3D printer for printing sand forms for foundry (2000x1000x1000 mm)• In-house foundry for casting Al moulds• CNC laser cutter• Wide range of machines for sheet metal forming
• Technical documentation + FAI• Technical documentation (production, assembly and packaging drawings)• First sample manufacturing + FAIR
• Serial production:• Rotational moulding production• Product assembling (customers can receive plug & play product)• Packaging and shiping to OEM
• Quality control:• Ultrasound wall thickness measurement on products• 3D product measurement• Pressure testing and life cycle testing of product• Internal laboratory for material analysis (impact/strengh and chemical testing)
• Certification process (e.g. fuel tank certification according to ISO EN 21487)
We manufacture moulds suitable for rotomoulding with three different technologies:• Sheet metal moulds. • Cast aluminium moulds.• Moulds that are milled from block aluminium.
In our workshop we prepare mould surfaces according to the customers requirements (sand blasted or polished surface). Product quality is highly dependent on the mould quality, therefore moulds are manufactured from quality materials and are periodically maintained in our workshop.Roto can also apply changes to existing moulds (e.g. new revision of product required, changing parts of the mould).
TOOL WORKSHOP
Custom rotational moulding 5
SCOPE OF OUR SERVICES
Rotational moulding involves a heated hollow mold which is filled with a charge or shot weight of material. It is then slowly rotated (usually around two perpendicular axes), causing the softened material to disperse and stick to the walls of the mould. In order to maintain an even thickness throughout the part, the mould continues to rotate at all times during the heating phase to avoid sagging or deformation also during the cooling phase.Each product that is manufactured within the rotomoulding process can be from a wide range of colours or/and materials, UV resistant, resistant to most chemicals (depending on material type), multi layed and also in-mould features (threads, metal inserts, …) can be added to this product.
Powder Mold
Moldchanging
Heat
Two-axisrotation Cool Product
demolding
ROTOMOULDING PROCESS
Product design
Frame construction 5D block alumunium CNC milling
3D sand printing Printed blocks assembling Casting
Tool assembly/finishing 3D measurement + verification
We use following materials for wide range of applications:• Polyethylene (LLDPE, XPE)• Polypropylene (PP)• Polyamide (PA6, PA12)
- All mentioned materials (except for XPE) are 100% recyclable. -
6 Custom rotational moulding
Roto provides to customer a complete tank solution including sub-assemblies (suction, return, filling and venting fittings, level sender, …). —› PLUG & PLAY PRODUCT
After all the sub-components are assembled to the product, we carrying out 100 % quality control, which also includes leakage testing of every volume product (product is submerged under the water in a testing pool and inflated with air to industry standards (min. 0,2 bar for 5 min time period).
Every product receives the following quality control:• Visual inspection as per customer requirements.• Dimensional control and reporting of critical charecteristics.• Leakage testing and reporting.• Wall thickness control.• Functionality control.
Described control procedure is digitaly recorded and saved to MES (manufacturing execution system).
Leak tightness testing process
Assembly process Product marking - serial number
Packaging and storage
Visual inspection
Quality control
PRODUCT ASSEMBLING AND TESTING
Custom rotational moulding 7
PRODUCT ASSEMBLING AND TESTING MODULAR MOULDS - Investment costs saving
• Base of the mould + interchangeable segments = PRODUCTS WITH DIFFERENT CHARACTERISTICS (changed height, volume, …)
• Example: Fuel tank 137L / 271L (base part is the same + two interchangeable upper parts)
• Base mould + additional interchangable mould segments —› 6 different products (with different dimensions/volumes)
• Height change with added segments • Base mould width is changed with added segments
• OR BOTH
Modular moulds allows for interchangeable segments, where one segment of a product mould can be used and added to produce another product, therefore reducing mould costs.
IN-HOUSE CERTIFICATION PROCESS FOR FUEL TANKS ACCORDING TO EN ISO 21487; ABYC H-33 AND ABYC H-24 CERTIFICATION
In-house laboratory for certification process and professionally qualified staff to carry out following testing procedure:1. Quality inspection (characteristic accountability, verification and
compatibility evaluation).2. Leakage test at test pressure (20 kPa or test pressure= 1,5x filling
height from top surface of the tank).3. Storage of filled tank with the intended fuel for (at least) 28 days at
ambient temperature.4. Hydraulic pressure/strength type test.5. Pressure-impulse type test for petrol fuel tanks.6. Fire-resistance test.7. Leakage test after fire-resistance tests (up to 1,8 kPa).
We are also providing support for ABYC certification process.
8 Custom rotational moulding
STANDARD MARINE TANKS • Fuel tanks (diesel, petrol)
• Fresh water tanks• Grey water tanks• Black water tanks
In comparison to metal tanks and HDPE/PP welded tanks the benefits are:• Whole tank is one piece moulding —› no critical points on welds.• Unlimited geometry —› any free space on boat can be fulfilled.• Tank price is competitive in comparison to steel or welded (welded from HDPE/PP plates)
tanks.• No size limits —› Roto can produce up to 20.000 L size in one piece.• The moulds can be modular (products with different characteristics), to cover wide range
of products.• Lower tank weight in comparison to metal or HDPE/PP welded tanks.
If fuel tanks needs to be fire-resistance tested according to EN ISO 21487 the use of XPE material is needed.
Benefits of XPE material:• Achieve fire-resistance and pressure-impulse type test according to EN ISO 21487.• High stiffness and high impact strength properties.• Excellent ESCR and chemical resistance.• Excelent long term properties.• Available in specific colours.• XPE is already proved on market for long lasting period - in use for more than 50 years.
Benefits of ROTATIONAL MOULDED TANKS
Standard marine tanks & other marine equipment 9
STANDARD MARINE TANKS • Fuel tanks (diesel, petrol)
• Fresh water tanks• Grey water tanks• Black water tanks
diesel tank fresh water tank
sump box
grey water tank
waterlock
black water tank
Same mould can be used to produce fresh, grey or black water tanks.
Roto offers you:• Standard tanks available already on market.• To develop a project of custom tank design (fuel, water, …) for your marine vessel.
On next pages are collected Roto standard marine tanks available for the market.
Benefits of ROTATIONAL MOULDED TANKS
10 Standard marine tanks & other marine equipment
Petrol fuel tanks (XPE material)
Diesel fuel tanks (XPE material)
50 L Code: 59001
90 L Code: 59002
400 L Code: 59026
50 L Code: 59000
90 L Code: 59003
750
350
200
1295
864
762
337
565
1295
864
762
337
565
780
765
275
750
350
255
780
765
275
Standard marine tanks & other marine equipment 11
110 L Code: 59013
160 L Code: 59012
160 L Code: 59042
200 L Code: 59007
200 L Code: 59051
Petrol fuel tanks (XPE material)
975
690
284
1270
711
305
832
787
409
1200
640
370
942
762
448
942
762
448
12 Standard marine tanks & other marine equipment
Petrol fuel tanks (XPE material)
1143
826
397
965
851
502
273490
451
992
1443
556
1219
541
273490
451
992
1443
556
1219
541
1295
864
629
1714
1219
366
230 L Code: 59047
280 L Code: 59037
280 L Code: 59034
400 L Code: 59025
450 L Code: 59043
Standard marine tanks & other marine equipment 13
Fresh water tanks (LLDPE material)
306 762346
483
965
359
298
965
359
298
1035
330
330
1035
330
330
648381
216
972 270
343
45 L Code: 59050
80 L Code: 59038
80 L Code: 59032
100 L Code: 59028
100 L Code: 59045
14 Standard marine tanks & other marine equipment
Fresh water tanks (LLDPE material)
1700 555
630
1975
923
185
575
1335
1975
923
185
575
1335
1160 435
880
2615
1490
235
550
710
1950 555
630
360 L Code: 55181
525 L Code: 55183
600 L Code: 55184
800 L Code: 55182
1400 L Code: 55185
Standard marine tanks & other marine equipment 15
Fresh water tanks (LLDPE material)
900 300
350
900 300
500
205
620
1295
80 L Code: 7453
126 L Code: 7454
156 L Code: 7452
16 Standard marine tanks & other marine equipment
965
359
298
Grey water tanks (LLDPE material)
965
359
298
972
343
270
570 340
510
1035 330
330
762
483
306346
80 L Code: 59039
80 L Code: 59033
90 L Code: 59031
100 L Code: 59044
100 L Code: 59030
Standard marine tanks & other marine equipment 17
Grey water tanks (LLDPE material)
1270 200
475155
290650
1260
940
500
185
530
1260
940
500
185
530
1705
860
370
240 L Code: 55188
430 L Code: 55186
450 L Code: 55187
18 Standard marine tanks & other marine equipment
Black water tanks (LLDPE material)
1092
635
507
1300
985
810
230
500
1300
985
810
230
500
546203
298
972
343
270
972
343
270
762
346
483
762
346
483
28 L Code: 59024
80 L Code: 59036
90 L Code: 59031
300 L Code: 55179
430 L Code: 55178
Standard marine tanks & other marine equipment 19
250350
250
167
1925
2538
Other nautic equipment (LLDPE material)
Black water tanks (LLDPE material)
320 358
580
482
560
430
50 L Code: 7765
80 L Code: 7948
sump box Code: 55509
WORLDWIDE ROTOMOULDER
PRODUCTION FACILITIES
SALES REPRESENTATIVES
since 1974
w w w. r o t o - i n d u s t r y. c o m
ROTOtel: +386 (0)2 52 52 182
fax: +386 (0)2 52 52 171
industry@roto.si
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