Manufacture of large-volume plastic hollow bodies using the rotational sintering process – from design through toolmaking to series production.

Geratec GmbH & Co. KG

Gera · GermanyNew on Amplifa

20+ yearsExperience in plastics engineering

50+Employees

20Rotational moulding machines

GeraProduction site

up to 1 m³FDM printing part volume

About Geratec

Geratec is a specialized plastics factory in Gera, Thuringia, and a member of the Pallentin Group. The company produces large-volume, technical hollow bodies using the rotational process (rotational sintering/rotomoulding) – stress-free, seamless and with uniform wall thickness. The value chain covers the entire process: production-oriented CAD design and feasibility analysis, mould and toolmaking for rotational moulding (aluminium and sheet steel), series production on 20 rotational moulding machines, and post-processing with trimming, drilling, threaded inserts and assembly of ready-to-install assemblies. Materials processed include PE, HDPE, XPE, PP, PA6 and PE regranulate; in addition, tool-free large-format 3D printing (FDM) with part volumes up to 1 m³ is offered. The product range spans cisterns and industrial tanks, vehicle components for municipal machinery, through to furniture, kayaks and mobile sanitary facilities. Customers include, among others, Bucher Municipal.

Site: Gera
Processes: Rotational moulding & rotational sintering (rotomoulding), Mould & toolmaking for rotational moulding, Design & engineering (CAD, feasibility analysis, prototyping), Additive manufacturing / large-format 3D printing (FDM), Post-processing: trimming, drilling, threaded inserts, assembly of components, Design & Engineering (CAD), Mould & Toolmaking, Rotational moulding & rotational sintering
Materials: Polyethylene (PE), High-density polyethylene (HDPE), XPE (crosslinkable PE), Polyamide (PA6), Polypropylene (PP), PE regranulate, Aluminium (thermally conductive, for rotational moulds), Sheet steel (for rotational moulds)
Certificates: ISO 9001
Employees: 50+
Industries: Water management/container construction, Agriculture/agricultural machinery, Municipal technology & commercial vehicles, Automotive & mechanical engineering, Furniture & design, Sports & leisure

01
Design & Engineering (CAD)
02
Mould & Toolmaking
03
Rotational Sintering (Rotomoulding)
04
Post-processing (trimming, drilling, threaded inserts)
05
Assembly of components

Materials & Processes

Polyethylene

Standard material for robust, 100 % recyclable hollow bodies such as tanks and containers.

HDPE

High-density polyethylene

For parts with increased requirements regarding chemical and mechanical resistance.

XPE

Crosslinkable polyethylene

For particularly durable hollow bodies used outdoors.

Polypropylene

For applications with higher temperature and chemical requirements.

PA6

Polyamide 6

For technically demanding parts with high mechanical load capacity.

PE-Regranulat

PE regranulate

Single-origin recycled material for sustainable series products.

Alu

High thermal conductivity aluminium

Material for rotational moulds with ideal thermal properties.

Stahl

Sheet steel

Robust material for long-lasting production moulds in rotational moulding.

Rotomoulding

Rotational sintering

Flash-free process for seamless, large-volume hollow bodies with uniform wall thickness.

FDM

Large-format 3D printing

Tool-free production of functional prototypes and parts up to 1 m³ from CAD data.

Locations

Gera

Production site: engineering, toolmaking and manufacturing

Lot size: Small to large series
Materials: PE, HDPE, XPE, PP, PA6, PE regranulate

20 rotational moulding machines (rotational sintering)
CAD/CAM
Large-format 3D printing (FDM)

Parts & Products

**Cisterns & rainwater systems**Rotational sintering · Water management

**Industrial tanks (fuel, hydraulic oil)**Rotational sintering · Industry

Inside the production

Industries

Water management/container constructionAgriculture/agricultural machineryMunicipal technology & commercial vehiclesAutomotive & mechanical engineeringFurniture & designSports & leisureInfrastructure & environmentMobile sanitary facilities

Processes & technical limits

Processes	Tolerance	Max. part	Weight	Lot size	Materials
Rotational moulding & rotational sintering (rotomoulding)Plastics	–	–	–	Small series – Large series	PE, HDPE, XPE, PP, PA6, PE-Regranulat
Mould & toolmaking for rotational mouldingPlastics	–	–	–	–	Aluminium, Sheet steel
Design & engineering (CAD, feasibility analysis, prototyping)Engineering	–	–	–	–	–
Additive manufacturing / large-format 3D printing (FDM)Additive	–	1 m³ (part volume)	–	–	Plastics
Post-processing: trimming, drilling, threaded inserts, assembly of componentsAssembly	–	–	–	–	PE, XPE, PP, PA

1 Anlagen & Maschinen

Machine	Manufacturer / model	Quantity	Working area	Year built	Site
Rotational moulding machine (rotational sintering machine)	–	20	–	–	Gera (all locations)

Additional services

Design & Engineering (CAD)Mould & ToolmakingRotational moulding & rotational sinteringPrototypingPost-processing (trimming, drilling, threaded inserts)Assembly of componentsAdditive manufacturing (FDM parts up to 1 m³)

Reference customers

Bucher Municipal

Quality

Quality assurance accompanies every production step from raw material to finished product. Geratec is certified to ISO 9001 by TÜV SÜD and undergoes regular audits.

Evidence	Gera
ISO 9001