Efficiency, quality, and innovation drive technological advancement in manufacturing. One such advancement for rotational molding plastic is the introduction of SMART molding, a game-changer that offers our customers a competitive edge. This SMART technology is reshaping rotomolding by delivering unparalleled value to our customers.
Understanding SMART Technology
The SMART rotational molding machine, developed by Persico Industrial using SMART (Simple, Maintenance-friendly, Affordable, Reliable, Time-to-market) technology, made a significant advancement in the field of rotational molding. SMART technology redefined the conventional rotational molding through its compact, efficient, and highly productive system. This innovative rotomolder incorporates electric heating elements, integrated cooling, and continuous monitoring with numerous mold temperature probes. The positive impact of these features touches many aspects of the process, from energy consumption to product quality and flexibility.
Energy Efficiency and Environmental Stewardship
One of the most immediate impacts of SMART molding technology is its energy efficiency. Unlike conventional carousel-type molding machines that heat and cool the molds by cycling them through propane or gas-fueled large ovens and cooling stations, SMART technology uses electric resistance heaters directly mounted on the mold. By directly heating the mold with electrical elements and optimizing cooling with strategically placed fans, SMART machines significantly reduce energy consumption. This not only lowers energy consumption by 15 percent but also aligns with global efforts toward environmental sustainability.
Enhanced Quality For Rotational Molding Plastic Parts
The precision and control offered by SMART molding result in exceptional quality products. While conventional systems rely on preset times for heating and cooling control, the SMART technology offers continuous monitoring of air temperature inside the mold during the entire process and provides temperature control across different mold zones. This well-controlled process ensures consistent material properties and results in products with excellent dimensional stability, uniform wall thickness, and superior surface finishes. Uniformity of wall thickness is possible because the temperature is consistent at every part of the mold, even with double walls. If you require different wall thicknesses, this is possible, too, because each mold control zone can be at a different temperature. This innovative process uses fewer raw materials, resulting in lightweight products with minimal deformities. For customers, this provides additional flexibility and means receiving products that consistently meet their expectations.
Unprecedented Flexibility and Time-to-Market
Flexibility is another benefit of SMART molding. Variable or consistent wall thickness is just the beginning. The technology supports a vast array of materials, including LLDPE, MDPE, HDPE, XLPE, PP, and Nylon 6. This material versatility, combined with the system’s ability to produce a wide range of products with complex geometries and high-quality finishes, expands the possibilities for product development. This allows our customers to swiftly respond to market demands, explore new applications, and deliver customized solutions to their own customers, with a significant reduction in time to market.
Operational Efficiency, Reduced Downtime, Shorter Lead Times
SMART molding markedly improves operational efficiency. The compact design of SMART machines maximizes space utilization, while the system’s integrated features minimize manual intervention and facilitate quicker cycle times. Additionally, spiders, the frame that holds the mold, can be quickly swapped out, further streamlining production, reducing downtime, and increasing overall productivity. These operational efficiencies translate into faster delivery times and lower costs, directly benefiting our customers.
Increased Cost Savings
SMART technology introduces significant cost savings for our customers because of its innovative features that are not found on traditional rotomolding machines. Energy efficiency, material waste reduction, and operational efficiency all translate into cost savings. Its ability to heat molds directly with programmable electric elements maximizes energy efficiency, which saves money. This system also minimizes material use and waste while having the capability to produce parts with varying wall thicknesses. The elimination of conventional ovens and cooling chambers, coupled with rapid cooling systems, drastically reduces production cycle times, enhancing productivity and lowering costs per part. Additionally, the technology’s design for quick tooling changes minimizes downtime, while its advanced monitoring guarantees high-quality outputs and consistency, reducing the likelihood of defects and rework.
GVL POLY: Industry Leaders in Rotational Molding Plastic
As the first rotational molder in North America to invest in SMART rotomolding, we feel that investing in cutting-edge technology is an investment in our customer’s futures by reducing costs, providing shorter lead times, and helping them to become more competitive. When we combine this industry-leading equipment and rotational molding expertise, you can be assured that your tight tolerance part will always meet your expectations.
If you are ready to learn if rotational molding plastic is suitable for your project, reach out to our team. We are happy to answer your questions and collaborate with you to take your product from idea to realization.
