Behind the scenes in our product development: The spill pallets process

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.


Innovation: Customer centred development

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.

Innovation: Customer centred development

Our sump 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?

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:

  1. Tub body with molded-in grating supports for maximised load capacity.
  2. Seamless, completely liquid-tight and manufactured in a modern design.
  3. Red signal leak indicator gives greater safety and convenience.
  4. The tub and grating are made entirely of chemically highly resistant polyethylene with DIBt approval.
  5. Integrated drive-in pockets for accessibility from all sides for ease of loading and transportation.
  6. Stable grating with ergonomic handles, making the grating easy to remove e.g. for visual inspection and / or cleaning.

Buy now in the online shop  


Practical trials and approval procedures

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)
  • UV resistance
  • 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.

Practical trials and approval procedures

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 molds. As the mold rotates, the liquefied thermoplastic is deposited layer by layer on the walls of the mold. The result: a seamlessly manufactured, completely liquid-tight tub body. The molds 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 setpoints 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 molding compounds are regularly subjected to external monitoring.

More than 50,000 spill trays are produced annually at DENIOS.

Left to right:

Image 1: Plastic collecting trays from DENIOS are made of polyethylene (PE), a thermoplastic.

Image 2: The powdery polyethylene (PE) is stored in silos and filled before the rotation process.

Image 3: Hollow body molds are mounted on a mold carrier, opened and filled with a precisely defined amount of PE powder.

Image 4: 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.

Image 5: The process enables a seamlessly manufactured, completely liquid-tight tub body.

Image 6: 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.