petrol & diesel tanks fresh water tanks grey water tanks ... · custom rotational moulding 5...

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


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. -


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


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.


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


110 L Code: 59013

160 L Code: 59012

160 L Code: 59042

200 L Code: 59007

200 L Code: 59051


975

690

284

1270

711

305

832

787

409

1200

640

370

942

762

448

942

762

448



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


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



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



900 300

350

900 300

500

205

620

1295

80 L Code: 7453

126 L Code: 7454

156 L Code: 7452


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


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


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


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

[email protected]

petrol & diesel tanks fresh water tanks grey water tanks ... · custom rotational moulding 5...

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