ARM Thai 2010 Technical Seminar Roto Profit!

Presented by: Gary Lategan

The Rotomoulding Process

Polymer Additives Moulds Heating Cooling Post Moulding

Type MFI Grind Particle size Shape Shot Weight

Impact Modifier UV Internal release Thermal Stability

Type Thickness Position Rotation Speeds Shielding Air Movers

Burner Air Flow Transfer Distribution MFI PIAT

Fast Even Cooling Remove Inserts Hot Demoulding

Storing Jigging Machining Colour Testing Assembly

P1

P2

P3

A1

A2

M1 M2 M3 H1

H2 C1

C2

C3

J1

J1

J1

Moulded Part

Why do we need to do testing? Because it will help you! Make a quality part And SAVE Money

Material Specification Sheet

UV or NON UV Stabilisation PIAT

ARMO Dry Flow Funnel Test

Flow Test Bulk Density Test

Grind Quality
Sieve screen Analysis Particle size Particle size distribution Particle shape

Colour Testing
Pigment Test - Dry Blend Colour Dispersion Compound Colour Match After 24 hours Light Box or Torch Test

Compound Material

What pigment and What % Check for light penetration And colour dispersion

Visual Test

Inside Surface Outside Surface Section view or shaving

Measure, Control & Improve

Drop Dart Tests Minus 40 Freezer Temperature Monitoring

Measure, Control & Improve

Smell Shrinkage Warpage

Other important checks

Vent Tube Parting line Release Agent Check & Calibrate Scale

The right mould

Type of material And Thickness Frame Clamps Rotation Speeds

The right mould

Position on the spider Method of attaching Quick release the mould Hinges, Hinges, Hinges

The right mould

How many moulds on a frame What is the weight of the polymer Vs Weight of the mould, frame and arm Are we heating polymer or metal!

The right mould

Type of mould Mould wall thickness Inserts & Parting Line Release Agent - Internal

The right mould

Selection of mould for product Mould design Mould clamping Mould positioning Type of mould to use

The right machine

In my opinion it must be 3 station Now what is it you wish to mould? Carousel or Rock and Roll Oven

The right machine

Other important features! Temperature Control Pressure or Internal Cooling Try to work without platforms

So what have you done differently! Today Last week Last year Or are you happy to continue doing it the same for the rest of your life!

Temperature Monitoring and Control

Gives you the freedom to: Experiment every cycle! Make Real Time adjustment! Control Multiple skin and Foaming! Mould New Materials

Internal air temperature

The DNA of Rotational Moulding

250

University of Waikato University of Waikato

Roy Crawford Roy Crawford

PIAT (Peak Internal Air Temperature)

200

392oF

Internal air temperature

tem p eratu re (d eg C ) 150

D
100

B A E

212oF

50

0 0 10 20 30 time (min) 40 50 60

More important, how can we CONTROL and IMPROVE what we have MEASURED! To

Improve bottom line profit!

The Heating Cycle

350 INTERNAL AIR TEMPERATURE 300 OVEN TEMPERATURE 250 Temperature (C) OVEN TIME 200 COOLING TIME

572oF

392oF

150

100

212oF

50

0 0 5 10 15 20 25 30 35 40 45

350

375

650 Moulding Cycle Time (mins)

Measure, Control & Improve

The ideal Burner Performance High Flame Low Flame The oven fan speed Direction of flow shot blast the mould The rate at which the mould is heated NOT the oven

Measure, Control & Improve

The correct oven temperature When to stop to thicken up Rotation Ratios & Speeds Achieve optimum PIAT every cycle

The Heating Cycle

250

Internal air temperature

PIAT (Peak Internal Air Temperature)

200

C Heating rate should be about 30oC/min

392oF

tem p eratu re (d eg C )

150

This slope should NOT have D a double slope

100

B A
Build-up rate of plastic should E be about 1mm/min End of powder pool.

212oF

50

0 0 10 20 30 time (min) 40 50 60

The Cooling Cycle The cooling rate has a major effect on the mechanical properties of the moulded part and the cycle time! And yet it is the least controlled phase of the process !!

The Cooling Cycle

350

300

In the cooling stage you create the OVEN TEMPERATURE structure in the part
OVEN TIME COOLING TIME

INTERNAL AIR TEMPERATURE

572oF

250 Temperature (C)

200

392oF

150

100

212oF

50

0 0 5 10 15 20 25 30 35 40 45

850 Moulding Cycle Time (mins)

920

935

Measure, Control & Improve

Cool as fast and as even as possible Position fans for even cooling Demould at correct temperature

The Cooling Cycle

250

Internal air temperature

PIAT (Peak Internal Air Temperature)

200

Cooling rate should be C about 20oC/min

392oF

tem p eratu re (d eg C )

150

D
100

B A E

212oF

50

0 0 10 20 30 time (min) 40 50 60

Benefits of Temperature Control? Consistent quality! Reduced Scrap! Improved Output!

Increased Profit!

Moulding with

TEMPERATURE
is the

FUTURE!

TempLogger
Temperature Monitoring and Control

For more info please contact me

Gary Lategan +27 82 8883180 gary@rotosolutions.co.za

or visit our website for downloads!

www.rotosolutions.co.za

TempLogger
Temperature Monitoring and Control

Thanks to SCG & Comos & Thanks for your attention!