Pentas continues to expand its machinery

Mid-September 2021, we will receive and install a new rotational moulding machine from Reinhardt in India. This will be an expansion of our existing machinery, bringing our total to ten rotational moulding machines. This expansion will further support us in the growth we have experienced in recent years.

Sustainable and safe 

Sustainability was an important factor in our purchase of this new machine. It comes with a high-efficiency combustion motor which makes it highly economical. In addition, the oven walls contain insulation material that allows the oven to reach a maximum temperature of ±400 ˚C while keeping the exterior safe to the touch.

Production capacity and payroll expansion

With this new machine, our company is ready for further growth while we opt for expansion of our production capacity for large products with a maximum diameter of 2.5 m and a height of 2.8 m.

The rotational moulding machine will operate in three shifts five days a week. We are still looking for staff to operate the oven (in three shifts) as well as employees to post-process the products in the daytime shift. As such, we are expanding our payroll as well as our production capacity.

Curious about the possibilities of rotational moulding? 

Get in touch with us and we will tell you all about it. Whatever your question may be, we will be able to help you.

Pentas purchases adjacent plot to facilitate continued growth

The purchase of an adjacent plot of land marks Pentas’ continued expansion. The opportunity presented by the available plot to the northeast of the current grounds is welcomed with open arms. With a surface area of 10,000 square metres, it offers Pentas the ability to increase its warehouse capacity as well as add another production hall.

First things first though. In the months ahead, the new plot will have to be flattened to prepare the road towards our plans for the future.

Saving energy at the drawing board

Pentas Moulding from Almelo uses the cashback promotion by Overijssel Province for high-speed doors. But that is just a minor measure considering what the plastics specialist is undertaking to save and generate energy. ‘We created a plan to ensure our continuous commitment to saving energy’, says owner Marthijn Koorn. ‘We contribute to the energy transition in other ways as well, by delivering products for windmills, for example.’

From toys to agricultural machines

The family-run business was founded in 1975 as a designer or windsurfing boards and went on to become the ultimate specialist in custom plastic product manufacturing with rotational moulding. From toys to plastic parts for agricultural machines, flower pots, lamps and urinals. You will find Pentas Moulding’s products anywhere.

Pentas Moulding’s efforts

The process of melting plastics consumes a lot of energy. Pentas Moulding aims to make the process more energy efficient from the drawing board onwards. The designs are made as lightweight as possible. The company developed a ribbed structure a few years ago and was even able to patent it. Marthijn: ‘Lightweight construction reduces the energy consumption and benefits the environment in other ways as well. Such as by reducing the amount of raw materials and transportation.’ The company is also improving the insulation of their machines, mostly ovens, and has converted all lamps to LED lighting some time ago. In addition, they try to limit outage to a minimum. The roof holds 1,670 solar panels and high-speed doors have been installed.

Main driver

Pentas Moulding views its commitment to sustainability as a self-evident part of its operation. ‘As a company, we feel a responsibility to contribute to a healthy environment. For society, our staff and our clients. Because they, too, are finding it increasingly important to do business with suppliers who are committed to sustainability. Plus, it is simply part of good employer practice to tend to the world we work and live in.’

What other plans are in the pipeline?

‘We meet with our energy consultants on a regular basis to see what we can do. We want to install more solar panels. We will be checking our compressor system to ensure that no energy is lost due to leaks. And we will be upping the ante on our machine monitoring to improve efficiency. Plenty of plans!’

What other plans are in the pipeline?  

‘We meet with our energy consultants on a regular basis to see what we can do. We want to install more solar panels. We will be checking our compressor system to ensure no energy is lost due to leaks. And we will be upping the ante on our machine monitoring to improve efficiency. Plenty of plans!’

Rotational moulding compared to other production techniques

The plastics manufacturing industry has countless processes for the production of plastic products. In addition to rotational moulding, blow moulding and injection moulding are the most important ones.

Rotational moulding in a nutshell

Rotational moulding is a tension-free process of heating plastic powder in a mould to form a plastic product. In this production process, an  aluminium or sheet steel mould is filled with thermoplastic powder (usually PE or PP) and sealed. The mould is heated in a large oven while being rotated on two axes placed perpendicular to each other. As a result, the molten material is pressed against the mould wall to obtain its shape. Next, the product is cooled and removed from the mould. The thermoplastic is processed free of tension, creating an impact-resistant product in almost any shape imaginable. Production series range from 100 to 5,000 products per mould per year and have a weight of 0,5 kg to 300 kg.

Rotational moulding vs blow moulding

Blow moulding is another highly popular production method that involves molten plastic being extruded in a preform. Pressurised gas, usually air, then presses the molten plastic into the mould until it cools and hardens. Once cooled, it can be removed from the mould.

Rotational moulding Blow moulding
+ Tension-free product + Short cycles
+ Low investment costs + More material types possible
+ Design freedom + High degree of detailing possible

Rotational moulding vs vacuum moulding

Vacuum moulding involves plastic film being heated to the distortion temperature with e.g. an infrared oven. The heated film is stretched in or on a mould. A vacuum is created in between the surface of the mould and the plastic and as a result, the plastic is sucked into the shape of the mould. Next, the product undergoes a forced cooling process.

Rotational moulding Vacuum moulding
+ Tension-free product + Short cycles
+ Low investment costs + More material types possible
+ Design freedom + High degree of detailing possible

Rotational moulding vs injection moulding

Injection moulding involves molten plastic being injected into a mould under high pressure. As a result of cooling, the plastic sets and the part is created. Injection moulding allows for the manufacturing of complex parts. Due to the high production costs of the mould, injection moulding is mostly suitable for larger production numbers.

Rotational moulding Injection moulding
+ Low investment costs + Short cycles
+ Thick walls possible + More material types possible
+ Easy to produce hollow products

From idea to product, here is how Rotational Moulding works.

Every product starts as an idea. But the road from idea to a production-ready product is a speciality. Our speciality.  At Pentas Moulding, we have a lot of knowledge and experience in this regard. Once the product is ready for mass production, we can produce and deliver it by order. We will clarify the process below in several steps.

From design to finish

Whether it be fuel tanks, flower pots, mudguards or toys: all plastic products by Pentas are made in a similar way. The shape, dimensions and colour may differ but the steps we take are always the same. From design to rotational moulding and from assembly/finish to transport. 

The design

The design is the foundation of any product. In consultation with yourself, our client, we create the optimal design. We hear your wishes and requirements and analyse the entire assembly environment of the product. We consider all of this in the context of the possibilities and limitations of the rotational moulding process and are happy to share our many years of experience with you to avoid any pitfalls.

Within the predetermined framework, our  builders optimise the design for the rotational moulding process. Product design is not just about the shape of the plastic product, but also about its application. We install parts into the product routinely, such as level gauges, caps, hoses, etc. Our extensive supplier network allows us to rely on a wide range of this type of assembly parts. But that is not all. Our builders are also responsible for designing the production mould which is then produced at our own mould construction department.

 

The mould

Once we know the dimensions and shape of the product, we will build a production mould. This mould is used to make countless exact copies of your product. Once the series is completed, we store the mould at our warehouse for your next order.

Pentas only uses CNC moulds in order to guarantee products of the highest possible quality. Benefits include close tolerances, proper wall thickness distribution and tight division seams. In addition, CNC moulds are relatively easy to adjust should any design changes prove necessary.

Rotational moulding

 

We fill the mould with plastic powder and heat it until the powder, now a liquid mass, sticks to the hot mould wall. Next, the product is cooled at our cooling station. In order to ensure proper wall thickness distribution, the mould is rotated on two arms throughout the entire process. In the final step, the set product is removed from the mould which is filled with a new batch of powder for the next cycle.

 

Finish

Our professional technical staff finish the product. Based on specific post-processing instructions available on the production line in digital form, the product is finished. During the design phase, we take a critical look at this entire process. Support moulds, gauges and measuring equipment are designed in advance for critical dimensions or important shapes. We also consider what may go wrong in our production/post-processing process in advance and anticipate this by developing ‘Poka-Yoke’ solutions.

As a system supplier, we deliver more than the plastic product alone. We install assembly parts as well to deliver semi-finished products. This means your product is delivered ready-made and completely assembled. To enable all of this, we manage stock parts and supplier relationships ourselves.

Quality assurance

Pentas puts quality first. We go all out in order to meet the agreements made with our client and the expected quality.  One way of doing this is by conducting thorough quality inspections. Quality assurance staff go around our factory with tablets taking samples from our production series. Drawings with tolerances are compared to the actual product. In the event of any deviations, we will investigate the cause and solve the problem at the source. Every individual product must meet all of the client’s predetermined requirements and thanks to our thorough inspections, we make sure it does.

 

Transport

If your organisation does not have its own transport department, we can have your product delivered to the desired location. We do this in collaboration with professional carriers in the region. We are well versed in logistic techniques such as  Just-In-Time and Just-In-Sequence and work with them on a daily basis. 

Curious about the possibilities of rotational moulding? 

 Contact us and we will be happy to tell you more. Whatever your question may be, we will be able to help you. 

Efficiency thanks to robots

The high quality of Pentas’ rotational moulding is realised by our staff and our robots. Robots offer many benefits in terms of accuracy and efficiency. In this article, we will tell you all about the robots we deploy to manufacture plastic products.

High-precision work 

Technisch projectleider / Tekenaar / Constructeur

It’s all in the details, especially when it comes to mass-produced plastic products. Robots are extremely good at this. Wouter Koorn, production manager at Pentas:   “We use a total of 11 robots for various tasks including filling moulds with raw material, assembling plastic products and post-processing of products, such as milling and drilling. These are all activities that require extreme precision in order to guarantee optimal quality. Thanks to our robots, we can now do this even better than ever before.”

Computer-controlled post-processing 

After the cast product has been clamped onto a milling jig, the robot comes into play. Pre-programmed software controls the robot to drill holes in the product or mill pieces out. We program the software in-house which gives us flexibility and lowers the barrier of the process. This allows us deploy this technique in medium-sizes production series for efficient and stable post-processing.

Thanks to Pentas’ robots, you can rely on optimal accuracy and a high-quality finish. It has become extremely easy to create an exact reproduction of a product. Plus, robots are a cost-effective solution especially when it comes to high-volume series.

The benefits of robotised processing:

  • Cost-efficiency as less manual work is required.
  • Reproducibility provides a stable high-quality finish, now and in the future.
  • Robot accuracy is unparalleled, allowing for close tolerances to be achieved.

Curious about the possibilities? 

We would love to tell you more about how we can deploy our robots for your plastic products. Feel free to contact us for a consultation, no strings attached. 

The high quality of Pentas’ rotational moulding is realised by our staff and our robots. Robots offer many benefits in terms of accuracy and efficiency. In this article, we will tell you all about the robots we deploy to manufacture plastic products.

High-precision work 

Technisch projectleider / Tekenaar / Constructeur

It’s all in the details, especially when it comes to mass-produced plastic products. Robots are extremely good at this. Wouter Koorn, production manager at Pentas:   “We use a total of 11 robots for various tasks including filling moulds with raw material, assembling plastic products and post-processing of products, such as milling and drilling. These are all activities that require extreme precision in order to guarantee optimal quality. Thanks to our robots, we can now do this even better than ever before.”

Computer-controlled post-processing 

After the cast product has been clamped onto a milling jig, the robot comes into play. Pre-programmed software controls the robot to drill holes in the product or mill pieces out. We program the software in-house which gives us flexibility and lowers the barrier of the process. This allows us deploy this technique in medium-sizes production series for efficient and stable post-processing.

Thanks to Pentas’ robots, you can rely on optimal accuracy and a high-quality finish. It has become extremely easy to create an exact reproduction of a product. Plus, robots are a cost-effective solution especially when it comes to high-volume series.

The benefits of robotised processing:

  • Cost-efficiency as less manual work is required.
  • Reproducibility provides a stable high-quality finish, now and in the future.
  • Robot accuracy is unparalleled, allowing for close tolerances to be achieved.

Curious about the possibilities? 

We would love to tell you more about how we can deploy our robots for your plastic products. Feel free to  contact us for a consultation, no strings attached.