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Home / News / How to create a two coloured Rotational Moulded PE product

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1 January 2016

How to create a two coloured Rotational Moulded PE product

Rotational Moulding offers great flexibility and almost unlimited options. However, there are still some limitations when it comes to design possibilities.

Many projects require multi coloured products that would be perfectly manufactured with Rotational Moulding.

Multi coloured products are currently manufactured by adding various different coloured powders in specific areas of the tool, with the aim of preventing a homogeneous mix. This process has its limitations, especially when it comes to large items, and very rarely the final outcome can be predicted. No accurate distinction can be achieved between two colours when desired.

Lysis Technologies, have been working very closely with the rotational moulding industry across Europe and have responded to the demand for a perfectly multi-coloured moulding.

In this case study we will present the creation of a two-coloured product, developed with Polymer Developments UK Ltd

The product

The item is of approximate dimensions 1.7m by 0.5m by 0.2m. The top part is required to be of grey colour and the bottom is white.

The process

Rotational moulding is proven to be more efficient, as it is quicker and cheaper. The product is of high quality and weather resistance.

The way forward was to apply the colour-matched Lysis Technologies in-mould sprayed ink system. Polymer Developments applied their spraying skills and knowledge. Half of the mould was coated in the desired grey colour, using a spray gun.

Then, the tool was charged with PE powder and the rotational moulding process was carried out as normal. The result was a perfect two-colour polyethylene rotational moulded product, exhibiting a well-defined line between the coloured and non-coloured area (see fig. 1).

Figure 1: Perfect two-coloured polyethylene rotomoulded product

Benefits of the technology

Some of the benefits of the in-mould sprayed ink system from Lysis Technologies are the following:

Colour Customisation
Permanent result
Solvent, UV and weather resistance
NO aerosol cans to be used
Quick and easy application
Perfectly finished products
Cost Reduction in the overall process.
Other examples of products achieved with in-mould spray coating are on figures 2 and 3.

Figure 2: Perfect two-coloured polyethylene rotomoulded item with black ink system and white PE powder.

Figure 3: Perfect two-coloured polyethylene rotomoulded item with grey ink system and purple PE powder

Case Study – as featured on the BPF website here

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Testimonials

  • “Tesoplas and Lysis Technologies have helped me to turn my ideas into reality. It has been a co-operative relationship. C4 Polymers has had the ideas and Lysis the incredible know-how. My success would not be possible without their knowledge and willingness to listen to my needs and ideas.

    For me, the strongest point is the one to one support and bespoke material manufacturing service.

    They offer great support, and they listen to my company’s needs, which has been invaluable.”

    Farzan Ramezani, Managing Director C4 Polymers Ltd
  • “We have been working with Lysis Technologies for some time now and have found them to be incredibly helpful and knowledgeable. The relationship that has grown and has gone beyond a general customer/supplier relationship. They have become a solution provider. When we have an issue, they investigate, develop and answer never giving up until they have one that works not only in the laboratory setting but also within a full production environment. Well done guys!”

    Karen Drinkwater, Managing Director JSC Rotational Limited.
  • “We have been using Lysis Surface Enhancer for the last two years, it exceeds performance of other similar products; it has been particularly useful eliminating problematic pin holes on some of our products.

    We find Lysis great to work with as they are refreshingly innovative and continue to meet demands of their customers.
    We look forward to new products Lysis will bring!”

    Richard Thorne, Managing Director Tanks UK.
  • “We are very happy with the ink and its performance in our application. The coverage is good on all colours and better than expected. We were also impressed with its durability under our trials”

    Mark Sergeant, Stamford Products Ltd
  • “Producing value added parts by using in- and post mold applications by rotomoulding needs experienced suppliers with good products.

    This is not enough. The suppliers need to support the rotomolders constantly with their knowledge. A hard, tiring mission for the suppliers.

    Lysis is the company which has always supported us with high value products and knowledge, never turning the face away when there is a problem to solve.

    No wonder they grew so fast. “

    Celal Beysel, Floteks, Turkey
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