Persico SMART Machine vs. Traditional Moulding
Traditional gas-fired rotomoulding has served manufacturers for decades, but electric pre-programmed control systems are redefining what's possible. As the UK's first contract moulder to adopt the Persico Rotomoulding SMART Machine, Rototek is leading this transformation from conventional heating methods to electric rotational moulding technology, delivering high-performance plastic products.
Unlike gas rotomoulding ovens, the Persico SMART Machine uses direct tool heating (DTH) with programmable electric elements that are independently controlled to target specific areas of the mould. This enables exceptional accuracy throughout the rotational moulding process and eliminates the inefficiencies of heating entire oven chambers.
For our customers, this means access to a new level of process control, with real-time data feedback, improved material efficiency, and the ability to mould more complex plastic components. This technology opens new market applications while maintaining the fundamental benefits of rotomoulding – stress-free hollow parts without joints or welds.
ADVANCED TECHNOLOGY & PROCESS CONTROL
Traditional rotational moulding ovens rely on gas to warm a large chamber, which indirectly heats the mould. Gas ovens require pre-heating, manual temperature checks, and operator intervention. In contrast, the SMART Machine uses:
Electric heating elements embedded directly into the rotomoulding tool
Automated zone heating for fine-tuned temperature control and energy efficiency
Independent heating and cooling cycles
Real-time temperature monitoring and adjustment.
The rotational moulding process itself remains the same – polymer powder is loaded into a heated, rotating mould, forming hollow parts as the material melts and coats the interior surfaces. However, the Persico Rotomoulding SMART Machine's electric heating allows for multi-layer moulding, foam core integration, and advanced material combinations that traditional systems struggle to accommodate. Traditional gas systems also require more hands-on monitoring and manual adjustments that the SMART Rotomoulding Machine handles automatically.
CYCLE TIME & COST CONSIDERATIONS
The rotational moulding cycle time directly affects production throughput and production costs. Traditional gas ovens typically require longer pre-heating and cooling cycles, resulting in slower production speeds. In contrast, electric heating eliminates pre-heating delays. Power is applied instantly when needed, whereas gas ovens must warm entire chambers before productive heating begins.
While the SMART Rotomoulding Machine has a higher capital investment than traditional gas ovens, the operational cost advantages quickly offset this difference. The electric heating efficiency cuts down on power consumption and lowers production costs over time. Electric heating elements also have longer service lives than gas burners, with minimal maintenance requirements, reducing downtime and service costs.
The Persico Rotomoulding SMART Machine's controlled environment also optimises polymer usage, reducing raw material costs and wastage. Traditional gas heating can create temperature variations that can lead to material degradation, requiring excess powder to compensate for inconsistencies. Precise temperature control can result in up to 10% material savings during the rotational moulding process. While gas ovens are limited to standard polymers like polyethylene and polypropylene, the SMART Machine is also compatible with recycled and bio-based polymers. The system supports circular economy principles and environmental goals through reduced material waste.
HIGH-SPEC PRODUCT QUALITY & CONSISTENCY
High-performance rotomoulding requires even wall thickness distribution, and the Persico SMART Machine achieves this through precise heat control and continuous monitoring. The SMART Machine also offers expanded design potential for sectors like automotive, aerospace, marine, logistics, and more. The Persico SMART Machine can produce sharper angles, flatter surfaces, and complex details, thanks to automated precision and consistency.
While traditional steel tooling can sometimes create hot spots that might result in wall thickness variations or uneven cooling, which can cause warping, the SMART machine’s automated monitoring and controlled heating zones ensure every rotational moulding plastic product meets tighter tolerances, improving end-product performance.
SUSTAINABILITY & ENERGY EFFICIENCY
Environmental performance is a growing priority for procurement and engineering teams, and SMART moulding presents a clear advantage. The Persico Rotomoulding SMART Machine:
Eliminates direct CO₂ emissions from fossil fuel combustion
Supports carbon-neutral manufacturing initiatives
Lowers energy consumption through direct heating
Minimises waste due to consistent processing
Is compatible with recycled and bio-based polymers.
For businesses with carbon-reduction goals, the SMART Machine is an ideal opportunity to reduce your environmental impact without compromising quality. Forward-thinking manufacturers will appreciate the Persico SMART Machine's direct heating approach, which uses energy only where needed.
ADVANTAGES OF THE PERSICO ROTOMOULDING SMART MACHINE
If your rotational moulding project involves complex geometries or requires consistent repeatability, the SMART Machine is the superior choice for high-performance plastic components. It's ideal for technical applications, automotive components, marine products, and any application where quality consistency drives value. That said, traditional rotomoulding still holds value for durable plastic parts produced to your exact specifications. Rototek continues to offer both options to suit different needs and budgets.
By investing in the Persico Rotomoulding SMART Machine, Rototek is setting the standard for advanced rotational moulding technology in the UK. We are the first contract moulder in the country to offer this capability, which speaks volumes about our commitment to innovation and delivering better results for our customers. Our 30+ years of rotomoulding expertise, combined with this cutting-edge technology, complements our existing 250,000+ square feet of production space and commitment to more sustainable practices as a certified B Corp manufacturer.
From custom rotational moulds to design, tooling, quality control, post-production assembly, and global dispatch, Rototek delivers advanced rotomoulding technology to enhance your product development. Discuss your next project with our expert team.