The project has developed a comprehensive strategy for the reduction of cycle times in the process of rotational moulding. Reductions of up to 50% have been achieved with subsequent productivity gains of 40%. This has been achieved by developing an intelligent control system based on data collected from inside the mould during the process. This control system is reactive and self-correcting to allow operation by semi skilled operators on a 24-hour 7-day week basis.
This process control system allows much faster hotter oven cycles without the danger of overcooking and very rapid cooling cycles without the danger of warpage and distortion. Overall gains in productivity are dramatic without greater capital costs of machinery. The machines would be simple to operate whilst providing full data storage of all process data for quality tracking purposes.