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Behind the scenes in our product development: The spill pallets process
Ever wondered what goes into product design and development? Do you want to understand better the rigorous process of testing and modelling that goes into the best products? Many products that are standard on the market today were originally developed by DENIOS. Today we focus on the customer needs to ensure the storage of hazardous substances even safer, easier and more functional. High quality standards have top priority in both development and production.
Customer needs form the centre of our product creation. We are in constant dialogue with our customers. This allows us to get detailed observation and a deep understanding of requirements.
Certain standards are prescribed by law. We design and construct our spill pallets to meet all legal requirements.
The DENIOS team focus in further on providing additional fuctionalities and features that improve your everyday processes and work practices. For example, creating easy accessibility when using a pallet truck or forklift truck, designing integrated filling areas or adding leak monitoring systems.
We start by using theoretical calculations to check whether individual components and the overall product meet all the necessary safety criteria, such as load-bearing capacity and stability. The next stage of product development involves rigorous practical testing with prototypes.
Our spill pallet product range is constantly being developed, so you can be sure you are always getting the most up-to-date technological features. This is one of our core products and we respond to our changing customer needs and the product uses. With over 500 models, we offer the largest range of products in all of Europe.
Have you seen the new pro-line range?
The new pro-line spill tray made of polyethylene (PE), for 2 or 4 drums of 200 litres each, offers you maximum safety and convenience when storing aggressive liquids such as acids and alkalis. A modern, practice-oriented construction with innovative features:
Tub body with molded-in grating supports for maximised load capacity.
Seamless, completely liquid-tight and manufactured in a modern design.
Red signal leak indicator gives greater safety and convenience.
The tub and grating are made entirely of chemically highly resistant polyethylene with DIBt approval.
Integrated drive-in pockets for accessibility from all sides for ease of loading and transportation.
Stable grating with ergonomic handles, making the grating easy to remove e.g. for visual inspection and / or cleaning.
Through certifications we ensure that our spill trays meet all legal requirements. Spill trays made of plastic are so-called "unregulated building products" in Germany. For this, we have a general building inspection approval from the German Institute for Building Technology (DIBt). The general building inspectorate approvals are usually effective for five years, after which they must be extended.
A DENIOS plastic sump can withstand up to 24 tons of test load *
Before we apply for approval, practical preliminary tests are carried out in cooperation with an independent materials testing institute. Among other things, the following properties of the spill tray are put through their paces:
Stability and tightness (attempts to fill with sandbags or water)
Load or "traffic load" (tests with prefabricated steel weights, with PE collecting trays with 4 times the load)
Material compatibility (also checking whether the materials used are approved)
Additional long-term tests for the stability of tubs that are higher than 500 mm
As soon as we receive the positive test report, we submit the application for approval. After approval has been granted, the materials testing institute checks an initial sample again to determine whether all specified quality standards are being adhered to.
* Example relates to the DENIOS classic-line spill tray for 3 IBCs of 1000 litres. In order to obtain general building approval from the German Institute for Building Technology (DIBt), the tray must be safe with 4 times the load capacity over a testing period of at least 30 minutes.
In-house production and quality assurance
DENIOS spill pallets are manufactured in-house with high quality standards in place. We are a certified specialist company according to the Water Resources Act (WHG) and meet the qualification for the production of steel tubs according to DIN EN 1090-2.
Our plastic spill pallets are made of polyethylene (PE) and are produced in our in-house plastic rotation facility. Powdered thermoplastic is heated to the melting point in hollow body moulds. As the mould rotates, the liquefied thermoplastic is deposited layer by layer on the walls of the mould. The result: a seamlessly manufactured, completely liquid-tight tub body. The moulds are created beforehand in our in-house tool shop.
We have set up a factory production control system for both steel and PE sump trays and have this checked by a recognised testing agency. A drawing is supplied with every DENIOS product, on which all parameters to be checked (e.g. wall thickness and dimensions) are recorded. These are recorded with a special measuring device, digitised and recorded using an electronic measurement protocol. It is automatically determined whether all set points are adhered to. The most important property of the drip pan, its tightness, which is also checked again and to ensure standards are met. In the case of a PE spill tray, this is done by measuring the wall thickness (grid plan check). The PE moulding compounds are regularly subjected to external monitoring.
Plastic collecting trays from DENIOS are made of polyethylene (PE), a thermoplastic.
The powdered polyethylene (PE) is kept in silos and filled before the rotation process.
Hollow body molds are mounted on a mold carrier, opened and filled with a precisely defined amount of PE powder.
The polyethylene is heated to melting point. As a result of rotation, the liquefied PE is deposited layer by layer on the walls of the mold.
The process enables a seamlessly manufactured, completely liquid-tight tub body.
A wall thickness measurement is used to check whether the drip pan meets all of the target values. This is recorded in an electronic measurement protocol.
Safety in 2022: New at DENIOS!
Start the year 2022 safely - with numerous new solutions and services from the DENIOS world! Here are the highlights. Take a look at our new products, browse through the DENIOS main catalogue 2022 and discover new trade publications in the DENIOS Download Centre.
Whitepaper 3 strategies for efficient hazmat storage
Find out how you can achieve greater added value with hazardous materials depots from DENIOS and, in addition to safety-relevant factors, also realise optimum space utilisation and efficient workflows for hazardous materials storage.
From the idea to the product: This is how a plastic spill pallet is created
Take a look behind the scenes at DENIOS! We will show you how plastic collection trays are created at our company: From the initial idea from our innovation department, through the approval process, to the finished series product, manufactured in our in-house press.
The 7 biggest mistakes when emptying spill pallets
It is not uncommon for liquids to leak and this can happen at any time. But what then? How does the liquid get out of the tray? This is not as trivial as it sounds: when emptying drip pans, serious mistakes can happen. Here you can find out what you should never do under any circumstances - and how to do it correctly.
As a supplier and manufacturer of the largest range of collection trays, we can assure you: There is a suitable collection tray for every requirement. How to choose the optimal product for your needs, we reveal to you in the following.
The specialist information on this page has been compiled carefully and to the best of our knowledge and belief. Nevertheless, DENIOS AG cannot assume any warranty or liability of any kind, whether in contract, tort or otherwise, for the topicality, completeness and correctness either towards the reader or towards third parties. The use of the information and content for your own or third party purposes is therefore at your own risk. In any case, please observe the locally and currently applicable legislation.