Case Study: AquaPro

aquapro

From concept design to product prototyping and testing, Global Rotomoulding are passionate about developing innovative products and moulding plastic in a creative way.

In this case study, we take a look at the development process of one of our most unique product collaborations, the AquaPro, and walk you through the benefits of using rotational moulding for custom projects.

What is the AquaPro?

The AquaPro is a commercial, underground water storage system with a large capacity (over 1 million litres), and was developed in collaboration with Vinidex and Trymak. Due to its large size, it is primarily installed under places like shopping centres, office blocks and car parks. However, unlike most large underground water storage solutions — such as concrete tanks and injection moulded structures — the AquaPro was designed to be cost-effective, versatile, and modular.

The design

Similar to a puzzle, the AquaPro was designed to have rotomoulded components which seamlessly fit together and can be arranged in multiple configurations. The main advantage of having a composite structure (i.e. made up of several parts and elements) is that the tooling expenses are minimised and the system can be easily installed by regular drainage plumbers in areas that are usually difficult to access (e.g. heritage listed sites). With custom-designed rotomoulded joiners, the AquaPro was meticulously engineered to meet structural codes, resist external pressures, maximise water volume, and prevent leaking.

Rotomoulding technology

Moulding consistently accurate parts with dimensional stability can be challenging. However, with the latest rotomoulding technology and machinery, we were able to produce high quality, stress-free components with surface finishes comparable to those of injection moulding. Some of the benefits of using rotational moulding technology for the Aquapro include: low lead times for the moulds (2-4 weeks), the ability to run different moulds simultaneously on the same equipment, the ability to mould intricate components easily, and lower costs.

Global Rotomoulding are experts at producing custom moulds and products with complex shapes. If you’re interested in producing rotomoulded components, send us an enquiry or give us a call today: 1800 666 333.

Photo Credit: Vinidex Aquapro

Rotational moulding case study: designing a rust-free toolbox

The Global team have once again donned their hats as the Sherlock Holmes’ of rotomoulding! When approached by Booth Transport with an ongoing problem, the team put their sleuthing skills into action to find a solution. Discover how Global Rotomoulding solved the rust-free toolbox case for Booth Transport!

The case of the rusty truck toolbox

Booth Transport’s trucks carry hoses which were constantly leaking in their storage boxes, causing rust and corrosion. Booth found that they were frequently replacing these storage boxes at a large cost. In many cases the water was even leaking out of the boxes and onto the tray bed, causing further rusting. They approached Global with the issue in hope of initiating a collaborative venture which would have these two businesses working together to find a solution with the help of plastic.

The sleuthing process

Global travelled down to South Australia to assess the situation, recognise the challenges and discuss Booth’s options. They carried out the following steps that they’ve become known for in their dedicated custom plastic design services:

  • Recognising the key criteria.
  • Discussion with Trymark Design Engineers to design and produce concept drawings of the proposed product which met these criteria.
  • Constant reviewing of the product design to assess its suitability.
  • Quotes sent to Booth Transport for the moulding and labour costs.
  • Final design approved by Booth Transport.
  • Quotes gathered from several mould makers to obtain the best deal for value and money.
  • Final design sent to chosen mould maker (in this case, offshore).
  • Inspection of the moulding process at varying stages to ensure the mould met the stated specifications, dimensions and criteria.
  • Final mould shipped back to Australia to undergo rigorous testing and trials to establish the right shot weight, cook and cool times.
  • Making of jigs to assist with the demoulding process.
  • Final sample product sent to Booth Transport for approval.

 Cracking the case

This collaborative process resulted in the Booth Transport rust-free toolbox, which would house their hoses and prevent corrosion to their trucks. The toolbox is situated under the truck tray bed and is made of plastic to prevent rust from leaking hoses. Some of the standout features of the toolbox include:

  • Fully stackable
  • Rust resistant
  • Includes an easy finger grab recess
  • Has integrated handles and hinges
  • Has a variety of configurations
  • Includes a weather tight seal
  • Can be secured
  • Lightweight
  • Durable
  • Impact resistant
  • Easy to clean

Solving problems and creating opportunities

Global’s collaboration with Booth Transport not only assisted in solving their ongoing problem but also generated a new rust-free toolbox product for the transport market. Collaboration between industries is essential when opening up new opportunities and avenues for expansion. Global have a strong history of collaborations and continue to lead the way in innovative plastic design.

Does your company have a problem they think Global could assist them in solving? Contact Global today!

Case Study: TuffMate2000 Trailer

On land and on sea, in the air and in space — plastics are taking over the transportation industry!

We take a look at the development process of one of our most innovative plastic products, the TuffMate2000 Trailer, and discuss some of the benefits of using polyethylene on the road.

Case Study: TuffMate2000 Trailer

The Product Brief

The TuffMate2000 was a revolutionary product from the very beginning. Designed in collaboration with the team at Trailers 2000, the brief was to construct a poly trailer that provided all the benefits of a steel trailer, plus more!

It had to be attractive, rust-resistant, and strong enough to carry a heavy load without buckling. The mounting system also had to allow for a growing and shrinking process because plastic tends to fluctuate in size. Particularly, if it’s left out in the sun for too long.

Case Study: TuffMate2000 Trailer

An early prototype of the Trailer in our workshop.

Case Study: TuffMate2000 Trailer

Testing the double-skinned walls for strength.

A new vision for transportation

Before the introduction of plastic trailers, most trailers were manufactured from steel. This was a major problem for two reasons:

  1. Steel trailers rust and corrode
  2. Heavy trailers are not economical or safe to tow

For many years, people have worried about leaving their trailers outside in the rain, salt air, and harsh Australian sun for fear of holes, rust spots, and corroded parts. There’s nothing worse than running outside in a wild storm to put a tarp on your trailer because you’re worried about corrosion, am I right?

Case Study: TuffMate2000 Trailer

Discussing the benefits of the Trailer with our friends.

Case Study: TuffMate2000 Trailer

Working on the trailer body in our workshop.

Plastic so tough you can smash it with a hammer

The first issue we hoped to resolve by designing a trailer with rotationally moulded plastic was strengthening the structure. We used high impact resistant, UV stabilised plastic that won’t rust, dent, or fade. At first, we went with a single-skin design, but it started to buckle when exposed to heat. So, we incorporated a double-skinned design that’s so strong you can strike it with a sledgehammer and see almost no effect.

Don’t believe me? Just check out this video!

A longer lifespan with no repairs needed

The Tuffmate2000 was designed to outlast every other trailer on the market. You can leave it in your backyard all year round and not have to worry about keeping it out of the rain or the salt air.

We used plastic that is impervious to almost every chemical, so you won’t need to be concerned about cleaning materials or maintenance. And, we’re proud to say that all of our plastic products are 100% recyclable and eco-friendly!

 Are you interested in designing custom rotationally moulded products? Call us on 1800 666 333, or send us an online enquiry today to find out how we can help you!

Case Study: Ludowici Safety Guard

As the advantages of rotational moulding become more widely known, more product designers and developers are jumping at the chance to boost safety, efficiency, and productivity in the mining industry. One such product that we designed is the Ludowici Safety Guard.

Case Study: Ludowici Safety Guard | Global Tanks

Used by mining companies all over the world, this bright yellow shield helps to keep mining workers out of harm’s way. The guard operates in a harsh environment and is fixed to a machine that continuously and violently vibrates at a high frequency. Our job? To design a product that is virtually indestructible.

The product brief

The Ludowici Safety Guard needed to be the ‘Iron Man’ of all products — strong, yet light enough to be carried by one person, unshakeable in structure, and able to withstand all sorts of shaking, trembling, and powerful vibrational movements.

The guard functions as a protective cover over a series of large rotating masses that need regular maintenance, so it also needed to be manufactured in two halves that could join together with precision and accuracy using a ‘tongue-in-groove’ arrangement.

An innovative solution to a dangerous problem

Before the introduction of plastic safety guards, the mining industry exclusively used heavy fabricated steel guards that often required up to four people to safely remove. They were expensive to manufacture and vulnerable to rust and corrosion.

The first issue we hoped to resolve by designing a rotationally moulded safety guard was the weight. We reduced the need for additional components by including as many as possible within the moulding itself. For example, we ditched the old screw on handles, which were heavy and rattled whenever the guard was in use, and designed new handles that were incorporated in the primary mould.

Product development and testing

Prototyping and testing were a crucial part of the Ludowici manufacturing process because we needed to be sure that our design would hold up under pressure and work as it was supposed to. We rigorously tested the safety guard against numerous performance criteria and refined our design to meet the high-stress requirements of the mining industry. As we had hoped, it passed with flying colours!

With smart design and a substantial weight reduction compared to the original steel guards, the Ludowici was hailed a success. Today, it demonstrates the true value of rotational moulding and proves that good design can transform any average product into something amazing!

Are you interested in designing rotational moulded plastic products? Looking for rural vehicle accessories, water tanks, or agricultural products? Call us on 1800 666 333, or send us an online enquiry today to find out how we can help you!

CASE STUDY: BAFFLE BONES, A ROTOMOULDING INNOVATION

In this article, we take a look at the development process of the Baffle Bone, and walk you through some of the benefits of using custom-designed poly products in the transportation industry.

Rotomoulding Innovations: Baffle Bones

An innovative solution to a practical problem

As any good tank driver will know, liquid surge control is essential for road safety. However, after many years of trial and error, we have discovered that the traditional methods of liquid surge control (e.g. built-in baffles and baffle balls) have several fundamental problems:

1. Built-in Baffles are weak
We have found that tanks with built-in baffles are structurally less sound. This is because built-in baffles are typically welded in place and can cause a weak point in your tank. Over a period of time, these weak points will break down or fail and you’ll need to replace your entire tank (often at a considerable price).

2. Baffle Balls take too long to assemble
Baffle Balls are also not that effective because they have a tendency to unclip when the tank is filled too quickly. Their flat pack design also means that they take a long time to assemble and prepare.

So how do you control your liquid surges without causing a weak point in your tank? And what’s the best way to optimise your time more efficiently and stop spending hours upon hours assembling balls?

Baffle Bones to the rescue!

It took us some time and hours of prototyping, experimenting, and testing, but we believe we have come up with an innovative solution that actually works. Baffle Bones don’t require any extra assembly time, they are cost-effective to replace, and they offer strength and durability with no risk of weight-related collapse.

Rotomoulding Innovations: Baffle Bones

The development process

To ensure that our Baffle Bone design solved the fundamental problems that many tank drivers face on a day-to-day basis, we put them through rigorous testing. The custom-design and development process for the Baffle Bones looked a little something like this:

1. Concept design and world-class engineering
2. Complete product design with product specifications
3. High-quality mould manufacturing in our modern facilities
4. Comprehensive testing, verifying, prototyping, and regulation approvals
5. Tool making
6. High capacity manufacturing
7. Successful delivery

The advantages of using plastic in the transportation industry

Polyethylene is ideal for products in the transportation industry because it weighs next to nothing. This means that products, like our Baffle Bones, are substantially lighter than other liquid stabilisation products on the market today, and require significantly less energy, fuel, and manpower to move, install, and transport.

Our Baffle Bones also offer many other design advantages. For example, because the products are made from one piece of plastic, instead of welding or bolting together various pieces of metal, they are exceptionally strong. They have greater durability and will not fall apart due to weak joints or a heavy load.

Our food-grade safe, BPA-free plastic is also rust and corrosion resistant, which means that your transportation products will have a longer lifespan and you’ll spend less money and time on product repairs. Bonus!

 

Are you interested in creating a custom-designed poly product? Looking for a transportation product with great advantages? Call us on 1800 666 333, or send us an online enquiry today!a

Case Study: Aquapro

From concept design to product prototyping and testing, Global Rotomoulding are passionate about developing innovative products and moulding plastic in a creative way.

In this case study, we take a look at the development process of one of our most unique product collaborations, the AquaPro, and walk you through the benefits of using rotational moulding for custom projects.

aquapro

What is the AquaPro?

The AquaPro is a commercial, underground water storage system with a large capacity (over 1 million litres), and was developed in collaboration with Vinidex and Trymak. Due to its large size, it is primarily installed under places like shopping centres, office blocks and car parks. However, unlike most large underground water storage solutions — such as concrete tanks and injection moulded structures — the AquaPro was designed to be cost-effective, versatile, and modular.

The design

Similar to a puzzle, the AquaPro was designed to have rotomoulded components which seamlessly fit together and can be arranged in multiple configurations. The main advantage of having a composite structure (i.e. made up of several parts and elements) is that the tooling expenses are minimised and the system can be easily installed by regular drainage plumbers in areas that are usually difficult to access (e.g. heritage listed sites). With custom-designed rotomoulded joiners, the AquaPro was meticulously engineered to meet structural codes, resist external pressures, maximise water volume, and prevent leaking.

Rotomoulding technology

Moulding consistently accurate parts with dimensional stability can be challenging. However, with the latest rotomoulding technology and machinery, we were able to produce high quality, stress-free components with surface finishes comparable to those of injection moulding. Some of the benefits of using rotational moulding technology for the Aquapro include: low lead times for the moulds (2-4 weeks), the ability to run different moulds simultaneously on the same equipment, the ability to mould intricate components easily, and lower costs.

Global Rotomoulding are experts at producing custom moulds and products with complex shapes. If you’re interested in producing rotomoulded components, send us an enquiry or give us a call today: 1800 666 333.

Photo Credit: Vinidex Aquapro