Custom sizes & formats

When standard containers hit their limits — because dimensions, geometry, inserts or functions deviate from catalogue — rotomoulding is clearly the superior process. The reason is tool economics: rotational tools in aluminium or sheet steel typically cost €15,000–€80,000 instead of the €500,000–€3,000,000 needed for injection moulding or blow moulding. That makes even short runs from 20 units commercially viable.

Geometrically, rotomoulding supports wall thicknesses of 3–12 mm, dimensions up to 4.5 m edge length and volumes up to 25,000 litres in a single part. A unique advantage is the ability to integrate undercuts, double walls (for insulation) and metal inserts (thread bushings, reinforcement plates, drain valves) directly in process — no post-processing, no sealing issues.

For very short runs (one-offs, 1–5 parts) we offer a 'soft-tooling' approach with sheet-metal tools: tooling cost from €6,000, lead time 4–6 weeks. For series parts (from 500 units/year) we optimise the tool for reduced cycle time and higher surface quality.

Rotomoulding has design rules that differ clearly from injection moulding and blow moulding. Minimum radii on outer and inner edges should be 6× the wall thickness, draft angles typically 1.5–3°, surface stiffening through embossed kickers rather than ribs. Our DfM team (design for manufacturability) reviews every customer drawing against these rules and delivers substantive feedback within 5 working days.

For demanding applications we use FEM simulation (Abaqus, Ansys) to predict mechanical loads, temperature distribution and fatigue life. This is especially relevant for transport containers with static stack loads > 2,000 kg, pressure tanks with internal pressure > 0.5 bar, or parts with dynamic loading (vibration, shock, crash impact).

Material selection covers 20+ raw compounds: LLDPE, MDPE, HDPE, XLPE (cross-linked), PP, PA6, EVOH (barrier), UV-stabilised, flame-retardant (DIN 4102 B1/B2), antistatic, ESD-conductive, food-grade, USP Class VI, FDA-compliant. For specialty applications we compound custom blends on our own micronising line.

Every custom-format project runs through a structured stage-gate process: requirements workshop → DfM review → 3D design → prototype tool → pilot (1–5 parts) → customer acceptance → serial tool (with optimisations from the pilot) → first-article inspection report → serial ramp-up. Typical lead time from kickoff to serial launch: 12–20 weeks.

After serial launch we maintain the tool over the product's entire lifecycle — typically 8–15 years. That includes tool maintenance, change management (as customers evolve geometry or function) and strategic spare-tool inventory for critical parts.

For projects needing IP protection we offer exclusive tools with ownership transfer to the customer, plus NDA-protected development work. This is particularly relevant for OEM supply to automotive, medical devices and defence, where IP protection and spare-parts access over decades must be contractually secured.