Welcome to ARM’s Wednesday general session.

Paul Nugent

Crosslinked rotomolding material has long presented a problem in disposing of scrap material due to its thermoset nature post-molding. Polymer Link has developed a proprietary process of treating rotomolded crosslink scrap so that it can be either be reincorporated into virgin crosslink material or combined with LLDPE material for general purpose applications. After reincorporation, good impact and physical properties are retained.

The approach offers molders the possibility of circularity for molding crosslink, diverting waste from landfill and putting it to use in rotomolded parts. Polymer Link has also developed a series of recycled products with up to 30% PCR content that are used for a variety of applications including flame retardant components, furniture and high stiffness applications.

Rotomolders can take away An option for reprocessing rotomolded crosslink material as well as options for high-content recycled rotomolding materials.

Dave Sullivan, NOVA Chemicals & Bill Spenceley, Flexahopper

This presentation explores how molders can achieve significant reductions in natural gas consumption and cycle time using NOVA Chemicals’ TRx rotational molding resins. Laboratory testing and real-world trials with Flexahopper Plastics demonstrate TRx’s ability to achieve proper cure at up to 55°F lower Peak Internal Air Temperatures (PIAT) than traditional resins. These lower PIATs result in energy savings of up to 30% per part and, in all cases, enable faster cooling due to the material’s inherently more energy-efficient curing behavior. Notably, these results were achieved using a lower-melt 3.5 MI grade, highlighting that significant energy savings can still be realized with high-toughness, high-stiffness grades designed to meet North American performance standards for large parts. The study highlights how Flexahopper was able to tailor processing conditions based on production goals, whether prioritizing reduced energy use through lower oven temperatures or increasing throughput by shortening both the heating and cooling stages of the rotomolding cycle. Attendees will gain insights from Flexahopper’s experience and learn how the next generation of faster-processing roto materials, like TRx, offers a path to lower operational costs and improved sustainability in rotomolding operations.

Rotomolders can take away: attendees will gain insights from Flexahopper’s experience and learn how the next generation of faster-processing roto materials, like TRx, offers a path to lower operational costs and improved sustainability in rotomolding operations.

Dr Gareth McDowell, 493K Limited

493K has undertaken an exciting R&D project looking at the effect of weather on processing times and cooling rates of rotational moulding parts. Upon asking over 300 rotomoulders who were in attendance at his training seminars around the world, the unanimous feedback confirmed that the largest pain points found in their manufacturing facilities revolved around the lack of control of dimensional tolerances, i.e. uncontrolled shrinkage and warpage of parts. Dr Gareth will present his latest findings showing how mould cooling rates vary with different weather conditions and ways that moulders can modify their cycles to compensate for ambient weather changes. Understanding the effects of weather on our process will help us to explore just how deep its impact really goes on the quality of rotomoulded parts.

The value is derived from understanding just how much impact the weather has on the process and specifically on the dimensional variations that are experienced. 493K is working towards machine control compensation for these weather variations and intends to soon propose methods that moulders can utilise to ensure a more stable manufacturing system.

Przemysław Orlik, OREX Rotomoulding

This presentation focuses on comparing the gas-powered and electric versions of the Carousel rotomolding machine. Structurally, the machines are identical – the only difference is the power source.

As far as I know, no one has conducted such tests before. We carried them out to raise awareness about the differences in energy consumption and production costs. Rotomolders can take away detailed energy consumption of the carousel machine in electric and gas versions – comparison and summary of which one is worth choosing.

The time is now for the Rotational Molding industry to evolve from Spreadsheets – to Real-Time Data – to AI-based Data Insights. And we can do it.

Many plants are stuck in old scheduling methods (including paper and whiteboards) and late, un-actionable production and scrap data analysis. The same weekly reports, three days too late to make changes and reduce scrap.

We need to move faster, at the speed of real-time data, keep the ovens full, and manage costs and inventory better.
Customer demand, the evolving marketplace, and new AI capabilities have compelled us to visualize and create new methods to streamline and digitally schedule manufacturing, track inventory, and be able to act quickly to make changes that will move production from WIP to Ship.
As we streamline, we must take the opportunity to use data to plan, schedule, track and complete customer orders, labor and plant productivity, and margin growth better than ever before. We need real-time insight. Not more data. And be able to make faster decisions that yield greater bottom-line profit. This insight is available; and now, there are AI-capabilities that can be used plant-wide.

This presentation will review new proven methods that help rotational molders evolve their plant operations from paper scheduling and late data analysis, to use of real-time data and AI that provides immediate machine, inventory, worker, scrap and customer order status insight, and faster decisions. We will demonstrate new ways that rotomolders can utilize historical data and AI-based queries to get answers to “What if?” questions about trends, productivity and scheduling to quickly make decisions that increase order completion and margins.

Aldo Quaratino, Matrix Polymers

As global demand for rotomoulded products increases, the process itself remains burdened by long-standing challenges—lengthy cycle times, limited material choices, inefficient heat transfer, and recurring quality issues such as pinholes and voids. Despite its versatility, rotomoulding has seen minimal disruptive innovation compared to other polymer processing techniques. This presentation introduces a novel technology designed to significantly reduce cycle times and gas consumption, without compromising product quality. By enhancing heat exchange efficiency across the burner, air, mould, and polymer powder interface, the approach not only improves productivity but also reduces environmental impact. Join us as we explore how this breakthrough could signal a new era of efficiency and sustainability for the rotomoulding industry.”