When it comes to producing lightweight yet strong plastic products, rotational moulding is a trusted technique. But the final output largely depends on the materials used. One key ingredient in this process is the foam powder. Choosing the right foam powders for rotational moulding can directly affect strength, insulation, and product life. In this blog, we’ll break down how to make the right choice and why Brilsol’s Bril-Foam stands out in the industry.
What Are Foam Powders?
Foam powders are additives that are mixed with standard polymers used in rotational moulding. When heated, these powders release gases that create a cellular structure inside the product. This gives the product a foamed, lightweight core while keeping the outer shell solid and durable.
The right foam powder can help make hollow products stronger, more heat-resistant, and better at insulation. These are key traits for products like water tanks, containers, and other industrial moulded parts.
Understanding Rotational Moulding Powder
Rotational moulding powder is a plastic material, often polyethylene (PE), used in the rotational moulding process. It’s ground into a fine powder to allow even coating on the inside of a mould. Foam powders are often added to these rotational moulding powders to improve their final properties.
The quality of the rotational moulding powder affects how well the foam powder blends and performs. That’s why both the base powder and foam additive need to be of good quality and carefully selected.
Why Foam Powders Matter in Rotational Moulding
Here’s how the right foam powders can make a difference:
1. Strength with Less Weight
Foam powders create a lightweight inner structure while keeping the product’s outer surface firm. This reduces material weight without reducing strength.
2. Thermal Insulation
Foamed plastic naturally offers better thermal resistance. Water tanks, especially in hot or cold regions, benefit from this property.
3. Cost-Efficiency
Foamed parts use less plastic material, which can help reduce overall costs without affecting quality.
4. Improved Durability
The layered structure produced by foam powders gives extra support to the final product, increasing its life span.
Brilsol’s Approach: Quality That Speaks
At Brilsol, we have developed our own range of foam powders under the name Bril-Foam. These powders are designed to work smoothly with PE and other base materials used in rotational moulding.
Our foam powders are made with consistency and reliability in mind. They produce uniform cell structures inside the product, which helps in maintaining the strength and insulation quality.
What Makes Bril-Foam Different?
- Stable Cell Formation: Our foam powders create fine and even cells, giving a smooth finish and balanced strength.
- Thermal Stability: Bril-Foam works well at a range of processing temperatures, which reduces the risk of faulty products.
- Low Odour: Our powders do not give off strong smells, making them safer for workers handling the moulding process.
- Compatible with PE Foam: Bril-Foam mixes well with standard PE foam materials, making it easy to add to your current moulding system.
Where Can You Use Bril-Foam?
Bril-Foam is suitable for many products that need a mix of strength, low weight, and insulation. These include:
- Water Tanks: Our foam powder helps improve insulation, reduce weight, and add strength to plastic water tanks.
- Chemical Storage Tanks: The even foam structure adds resistance against pressure changes and improves safety.
- Ice Boxes and Coolers: Better insulation keeps the temperature stable inside these products.
- Furniture and Planters: Bril-Foam helps create lightweight but strong furniture pieces for indoor and outdoor use.
Factors to Consider Before Choosing Foam Powders
When picking foam powders for rotational moulding, consider the following:
1. Cell Size and Distribution
Smaller, even cells improve product strength and reduce surface defects.
2. Processing Temperature Range
Make sure the foam powder matches your moulding machine’s temperature range.
3. Material Compatibility
The powder should blend well with your base rotational moulding powder.
4. Storage and Shelf Life
Foam powders should be stored in a dry place and have a long shelf life without affecting performance.
Brilsol provides detailed product data to help customers make informed choices. Our technical team also supports customers with the best usage guidelines.
Tips for Better Results During Moulding
To get the best performance out of Bril-Foam:
- Preheat the mould correctly.
- Measure the foam powder accurately for each batch.
- Allow proper cooling time to avoid internal stress.
- Clean the mould between cycles to prevent buildup.
Following these steps along with using high-grade powder like Bril-Foam ensures smooth production and longer product life.
Why Choose Brilsol?
Brilsol is focused on delivering materials that simplify the production process. We keep our products easy to use, consistent in quality, and backed by real customer feedback. Our foam powders are tested in-house and by industry partners to meet the daily needs of rotational moulding operations.
Our support doesn’t stop at the product. We offer advice, training, and technical help to companies who are looking to get better output without increasing costs or complexity.
Choosing the right foam powders is not just about picking any additive. It’s about finding one that matches your base material, your moulding process, and your product goals. Bril-Foam by Brilsol gives you that balance — quality, reliability, and ease of use.
If you are into manufacturing tanks, boxes, or other moulded parts, and want better performance without adding weight or cost, Brilsol is ready to support you with a foam powder you can count on.