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Advanced Manufacturing Technology to Boost Production Capacity for Long Fiber Injection Molding Leader

Advanced Manufacturing Technology to Boost Production Capacity for Long Fiber Injection Molding Leader
ROMEO, Mich. -- Award-winning Romeo RIM (, the world’s innovative leader in custom reaction injection molding and composite solutions, is proud to announce it has officially “flipped the switch” on its brand-new, innovative rotary system. The new fully automated system -- incorporating multiple presses and off-line mold changes -- will significantly boost production capacity for the company which continues to see increasing interest in its long fiber injection (LFI) molding solutions.

“With the applications of LFI virtually limitless, this new rotary system will open up new markets to us as well as help us continue to serve our existing customers that are seeing increasing growth,” Randy Johnson, president and CEO said.

As an example, Johnson pointed to customers in the spa industry which is seeing a renaissance of sorts, judging by positive momentum permeating this year’s annual industry show in Atlantic City. With spa manufacturers needing to start production in the spring of 2017 for the next model year, the timeliness of having the new rotary system fully operational now will benefit existing Romeo RIM customers as well as new ones.

“The rotary opens our capacity way up to almost 30,000 spas, which translates into roughly fifteen percent of the entire spa market,” he explained.

The new rotary system takes Romeo RIM’s ability to produce lightweight, class A finish, and b-side detail products with superior stiffness and strength to a whole new level. Occupying roughly one quarter of the company’s main manufacturing facility on its 67.5 acre innovation campus north of Detroit, the system is about the size of a hockey rink, with a large 100-foot oval track. The system consists of seven individual presses that run around the oval track, each containing its own unique mold, which can be in mold painted its own unique color. The press is able to run 15ft per minute, which ultimately delivers a complete molded part in about a minute. In addition to its incredible speed, the equipment is desired to always be running. Mold changes are completed off-line by shuttling a press out off the oval.

If maintenance must be completed to the LFI system, this can be done without shutting down the press because there is a redundant backup. Since the equipment is completely robotically controlled, the part is produced the same way every single time, no variations like you get with many other composite manufacturing processes.

The rotary LFI system is already delivering value to the Agriculture industry by producing siding for large farm equipment. They are realizing the low cost benefits of in mold paint, so the OEM’s no longer have to pay for a secondary operation in top coat painting.

The spa/hot tub industry is benefiting by producing patterns and looks on their siding that were previously not available to the industry, all thanks to in mold painting. Their products look better, but are now stronger, lighter, and more impact resistant to the occasional baseball or lawnmower damage.

In transportation and truck industries, weight is everything. With LFI, composite parts are produced at lower weights. Producing body siding, or even interior parts, will reduce overall vehicle weight. The use of in-mold paint with it also provides lower costs for the finished components as well as they can be textured to simulate leather, wood grain, or geometric patterns that are popular in industry today.

Other markets that would benefit from using LFI are utility terrain vehicles (UTV), recreational vehicles (RV) and motor homes, building materials, medical enclosures, electric vehicles, and industrial portable equipment, just to name a few.

According to General Manager Tim Howell, the genesis of the rotary came from having very high demand in LFI that was coming close to exceeding our capacity limits, especially crucial when you still have to complete routine maintenance.

“When designing the rotary system, we wanted to be sure that we eliminated any issues relating to that. We accomplished our goal by having redundant systems in our equipment to ensure maintenance could be performed and not shut down the equipment down. Mold changes are now done off-line and don’t shut the system down, the previous equipment would need to be taken down for 30 minutes with each mold change, not anymore,” he explained.

Additionally, Romeo RIM wanted to ensure for a very flexible system, so it can run parts for seven different customers all at the same time, each having their own unique color with robotically applied in-mold paint.  This shortens lead times to customers and allows for the ability to quickly react to changes in customer demand.

The introduction of the rotary system is fully supported by Romeo RIM’s commitment to lean manufacturing in its quest to continue to offer a unique combination of material formulation, long fiber reinforcement in product sizes larger than anyone else can make. In addition to investing in exciting new technology like the rotary, Romeo RIM continues to hire and train smart, experienced, and innovative workers to ensure the highest-quality engineering design and custom material formulation at the front end, along with excellent delivery and customer support at the back end.

To learn more about Romeo RIM’s design, engineering, and support experience in reaction injection molding, LFI, and in-mold painting email [email protected], call (586) 336-5877 or visit

Award-winning Romeo RIM is the world’s innovative leader in custom reaction injection molding and composite solutions. The company serves markets including transportation, heavy truck, agriculture and construction, spa, and rail car with complex engineering applications and a commitment to quality customer service. Our experienced, growing workforce combines years of technical and industry knowledge with a spirit of creativity to develop the next generation of long fiber injection (LFI) molded products and technologies. Romeo RIM’s lean manufacturing and operational excellence enables us to build a strategic connection with engineering and purchasing professionals up and down the supply chain, aligning our strategy with their strategy to form strong, lasting relationships. For more information, visit

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Advanced Manufacturing Technology to Boost Production Capacity for Long Fiber Injection Molding Leader


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