ROTOMOULDING D I V I S I O N

SHAPING
ideas
since 1976

Design,
Moulds,
Equipment,
Machinery
and Prototypes
 SHAPING
ideas
since 1976

1 Model-maker Pierino Persico at work in 1976 2 Foundry 3 Modeling 3 Workshop

Hall of Fame
The Rotational Moulding Hall Of Fame award is the highest honour bestowed by the Association
of Rotational Molders International (ARMI) on a single individual for outstanding service and
contributions to the rotational moulding industry. At the ARMI meeting held in Minneapolis,
Minnesota, U.S.A., on 29 September 2009, the Hall of Fame award was given to Pierino Persico, who
became the FIRST ITALIAN RECIPIENT of this honour (and only the third one in Europe).
 ROTOMOULDING D I V I S I O N

Persico Group
Persico was established as a wood moulding factory in 1976 by Pierino Persico and in a few years
became one of the most skilled and versatile mould engineering companies worldwide. Today the
company consists of the following divisions:

• Automotive: manufactures aluminium and steel moulds for the production of interior upholstery and
trim, heat and sound insulation systems, and composite body panels for cars and industrial vehicles.

• Rotomoulding: manufactures aluminium rotational moulds. In addition, Persico provides know-how,

equipment and development from idea to finished product.

• E ngineering: provides complete automation processes and systems. At first the division was
dedicated to meeting automotive market demands, then it expanded to include the rotational
moulding industry, and now just about every field, with a focus on the aeronautical, railway and wind
power sectors.

• Marine: undertakes all types of nautical projects, from concept design to finished product, and
shares the same mission as the other divisions: to ensure full customer service.

• Aerospace • Aeronautics: specializes in advanced composite moulding for the aeronautics and
aerospace industries. In the space field, the company boasts a history of excellence in developing
and producing added-value aluminium, titanium and carbon equipment for the manufacture of
civilian and military satellite components.

Persico’s Research & Development Department automation lines and presses to carry out tests on
collaborates with all corporate divisions on the moulds produced by the divisions. R&D can
technological innovation initiatives to improve also provide pre-series production to test mould
product quality standards, create new functionality and reduce the time for creating
products and optimize production processes. initial samples for fairs or final customers, which in
The department uses rotational machines, turn need to optimize their production times.
 Prototypes

Machinery

Moulds
Design

Milling
Casting

Persico Rotomoulding
The Rotomoulding Division is world leader in the production of rotational moulding equipment.
4
It is outfitted with 3- and 5-axis CNC milling machines for rotational moulds, a CAD/CAM tooling
department and a specialized in-house foundry, with know-how and machinery exclusively dedicated
to rotational moulding. Moreover, the Rotomoulding Division is supported by an extensive technical
and sales assistance network. This allows the division to provide a complete range of services: from
concept to design, engineering, manufacture of prototypes and models, moulds and automation
systems for rotational moulding.

Rotomoulding technology can be applied to numerous sectors:

Lighting, Vases, Furniture, Art, Medical, Kids&More, Sport, Agriculture, Cleaning, Conteiners, Transport,
Construction, Urban Design.
 ROTOMOULDING D I V I S I O N

Design&Engineering
We formulate our design proposals and display them instantly on the screen, which permits quick
design development in direct collaboration with our customers. Our designers and engineers have
complete mastery of rotational technology and are thus able to take full advantage of the flexibility
of rotational moulding. The design proposals can be used to generate dimensioned drawings for
modelling purposes or 3D files for direct CNC mould production. The Persico Engineering Department
makes use of latest versions of the major 3D CAD systems (Omnicad, Catia, Solid Works, UG, Pro-E).

• Frame design with Finite Element Methods (FEM)

The use of structural FEM:

1. Optimizes frame design by adopting the optimal cross-section and structure.

2. Allows reducing the number of closure points (if desired, in combination with the Spider closure
system).
3. Minimizes total weight.
4. Aides in choosing the best springs to ensure uniform closure force.

• Laser frame design and manufacture

Innovative frame design using 3D files enables us to collaborate with our customers in the design
stage, as well as during the frame laser cutting process. The frame is produced during the milling
stage or during aluminium shell casting. Executing these two processes in parallel allows us to reduce
dead time.

5
 Casting Dept
Persico Rotomoulding Division designs and manufactures:

• Scale models, which are constructed utilizing the most advanced rapid prototyping systems and are
used to check the part right from the design stage.

• F oundry models, which can be constructed out of any material either by hand or on CNC
machines. Models can be used as a prototype for the customer or as the starting point for the
manufacture of cast aluminium moulds.

Milling Dept
Persico was the first Italian company to use milling machines of dimensions up to 25 x 7 x h 3.0 m, as well
as other in-house milling machines (dimensions: 17.5 x 6.5 x h 2.5 m and 8.0 x 4.5 x h 2.0 m).
Precision and speed: Persico’s milling machines – some of which are of the latest generation with
magnetic motion control – execute single-block models and various types of moulds in such a short
time and with such high quality and dimensional precision that the results cannot be matched by
manual construction.
Greatly reduced production time: Persico can count on the support of several out-of-house milling
machines of various dimensions, some with magnetic motion control, in processing all project models
and moulds.

6
 ROTOMOULDING D I V I S I O N

Surface treatments and finishes

Persico offers a variety of surface treatments and finishes that extend the useful life of moulds and
enhance the look of the moulded plastic parts. Hardening treatments or Teflon coating can be used
on the flanges alone or on the whole mould. Aluminium mould surfaces can be polished to make the
moulded plastic parts shinier. Moreover, the aluminium moulds can be finished in such a way as to faith-
fully reproduce the look of existing materials, such as wood, rock, terracotta, skin, antiqued materials
and others.

Different treatments in different colours

COATING COATING COATING COATING

Treatment
TREATMENT 1 TREATMENT 2 TREATMENT 3 TREATMENT 4
Colour Green Black Brown Blue
Effect on molded part half-luster matt shining very shining
Gloss 40°-50° 15° 45°-55° > 80°
Max treatment 260°C
230°C 205°C > 300°C
temperature resistance (280°C intermittent)
Release Qualities Very good Acceptable Very good not releasing
Abrasion resistance Very good Acceptable Very good Good
Chemical resistance Very good Very good Very good Acceptable
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 Moulds
• Cast moulds

An in-house foundry dedicated to cast rotomoulding allows Persico to obtain porosity-free moulds
with various surface finishes.

Agriculture

Marine

Agriculture

• Easy Moulds

Easy moulds are ideal for prototyping parts that do not require special care with regard to appear-
ance.

- No model is constructed (a special foundry process allows for bypassing the modelling stage).
8 - Assembly and internal profile are not given any special treatment.
- Surface finishing is done completely by shot-peening or sandblasting.
- No frame is provided and the mould closure is achieved by clamps mounted directly on the mould
flanges.

Trucks
 ROTOMOULDING D I V I S I O N

• CNC Moulds

- Persico’s 5-axis CNC milling machines produce high-quality moulds in much less time.
- CNC milling means greatly reduced milling and delivery time
- Higher quality, tighter tolerances and improved aluminium properties for large moulds.
- Extremely precise flange assembly and internal surface profile.
- Better surface finish from aluminium block than cast aluminium.
- The greater the complexity, the greater the benefits of CNC-machined moulds compared to cast
moulds.

Medical

Furniture

Agriculture
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 Leonardo – Fully Automated Rotational Machinery

LEONARD
Leonardo is the pinnacle of moulding technology. If traditional
rotational moulding, blow moulding and injection moulding do not
r o t o m o u l d i n g m a c h i n e meet your specific application needs, Leonardo is the clear choice.

ADVANTAGES:
- Cycle repeatability
- Quality consistency
- Thickness uniformity
- Complex surfaces

Electric Leonardo

LEONARD
Fully electric Leonardo rotational moulding machine. The inno-
vative heating system on the new machine consists of a series
r o t o m o u l d i n g m a c h i n e of resistors applied directly on the mould surface. Since the dia-
thermic oil mould heating and cooling systems have been elimi-
nated, the machine has a much smaller environmental footprint.

10

Claudia Persico: “Persico helps its customers all services: design, models, moulds and moulding
the way through every stage of the production machines, both traditional and innovative, such
process. Even customers completely new to rota- as LEONARDO. We assist our customers so that
tional moulding can, with technical support from they will acquire the rotational moulding know-
our staff, develop their ideas into finished prod- how they need in order to obtain the product
ucts. We provide a full range of products and they want using our machines.”
 ROTOMOULDING D I V I S I O N

SMART - LEONARDO TECHNOLOGY

smart
LEONARDO TECHNOLOGY

The latest in rotomoulding machinery!

Simple: All-in-one, compact production

box.

Maintenance friendly: Remote control

assistance plus ad-hoc training programme.

Affordable: Attractive ROI due to benefits

such as a shorter cycle, raw material savings
and reduced energy consumption.

Reliable: 10 years of Leonardo technology

and know-how from Persico automotive
division.

Time-to-market: new material market

potential, healthier and safer production
process, perfect solution for entry into the
rotomoulding market.

Smart available machine sizes

Moulds heated by electrical resistors, with heating process fully controlled and monitored by a PLC.

H = 1400 mm - 55 inch.
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Φ B = 1700 mm - 70 inch.
Φ S = 2200 mm - 86,6 inch.
 R&D Dept.
New technologies implemented on Leonardo - the fully automated rotational machinery

The rotomoulding market has huge potential, but today it is hampered by the limited offering of poly-
ethylene alternatives.

Some materials already on the market have not yet found their best use in the rotomoulding sector,
because they can cause problems during the traditional moulding process, due to the lack of automa-
tion and process control.

Therefore Persico’s R&D team has focused on improvements concerning materials:

PA6: starting with caprolactam chips fed through a dosing unit, rotomoulding of components on a
New Leonardo electrical heating machine.

Transparent polycarbonate: rotomoulding on a New Leonardo electrical heating machine

using a vacuum technique and specially treated moulds.

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PLA: an innovative material to achieve moulded components with a super glossy surface.
 ROTOMOULDING D I V I S I O N

Claudia Persico: “Persico designs and develops custom moulds and automation systems. Rounding
out our service offering is the know-how we share with our customers.”

TP-Seal®: a dual layer solution for production of gasoline tanks and to solve permeability test
problems.

BIO-TPSeal®: PLA combination (TP-Seal + PLA) with a high gloss effect.

Courtesy of TOTAL Refining & Chemicals

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Multylayer: Multi-layer complex moldings can easily be achieved using automated material
delivery. Accurate temperature control helps ensure that foam depth and inner layer thickness
are controlled. Mold and Air temperature profiles can be used to accurately time the addition of
each layer of material. Soft material can be ‘over-molded’ into specific areas on a part (as sealing
surfaces or handles, for example) by control of heat flow.
 Rotational moulding is a simple process, composed of four basic phases:

1. A pre-weighed amount of powdered or liquid plastic is placed in one

half of a thin-walled, hollow aluminium mould, which is mounted on
the arm of a rotomoulding machine. The mould is then closed with
clamps or bolts.

2. The mould is then biaxially rotated on perpendicular axes and moved

into an oven where heat is applied. The aluminium mould becomes
hot and the powder/liquid tumbling inside rises in temperature. Hot
material sticks to the mould in successive layers to form the part.

3. W hen the material has melted and has been consolidated, the
mould is moved to a cooling station, where forced air, water mist or
a combination of both is used to bring the part temperature down to
a point below the crystallization or solidification point of the material.
The biaxial rotation continues to prevent the material from sagging.

4. Once the part is cool, the mould is moved to an unloading station,

where the part is removed. The mould is then ready to begin the pro-
cess again.

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 Where we are

400 SPECIALISTS AND 80,000 SQUARE METRES TO ENSURE WORLDWIDE SATISFACTION

Automotive Rotomoulding Marine Engineering R&D

via Vasvecchio, 6/b24027 via G. Camozzi, 8 via Lombardia, 4 via lombardia, 8 via R. Follereau, 5
Nembro (BG) Italy 24027 Nembro (BG) Italy 24027 Nembro (BG) Italy 24027 Nembro (BG) Italy 24027 Nembro (BG) Italy
p +39 035 4531611 p +39 035 4531811 p +39 035 4531711 p +39 035 4531711 p +39 035 4531611
f +39 035 4531612 f +39 035 4531812 f +39 035 4531752 f +39 035 4531686 f +39 035 4531612
automotive@persico.com rotomoulding@persico.com marine@persico.com engineering@persico.com r&d@persico.com
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Our companies Our partner

P.I Torrubero Terenzio Presse Persico Usa, Inc. Ferry Industries Inc.
Av. Constitución 3 via Vasvecchio, 6/b 2950 Technology Drive 4445 Allen Road . Stow,
Museros 46136 24027 Nembro (BG) Italy Rochester Hills, MI 48309 Ohio 44224 -1093 USA
Valencia, Spain p +39 035 4531611 p 001-248-299-5100 www.ferryindustries.com
p +34 961 452 135 f +39 035 4531612 f 001-248-299-5200
f +34 961 452 136 info@terenziopresse.com alberto.carrara@persico.com
info@futurefibres.com www.terenziopresse.com sz.rotomoulding@persico.com
www.futurefibres.com
 ROTOMOULDING D I V I S I O N

shaping
ideas
since 1976

Persico Rotomoulding
via Camozzi 8 • 24027 Nembro (Bg) Italy • p +39 0354531811 • f +39 0354531812
persico.com • rotomoulding@persico.com