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Fuel tank parts

Fuel tank parts (HDPE)

Case Background

HDPE is an upgraded blow molding material, known to be difficult to retain its shape after production but with very high strain coefficient.
Those who succeed in using this material always end up with very high cycle times, this costs money. We have succeeded in making moulds that can process this material at low cycle times without deforming the finished product after production.

Penne NV is a leading manufacturer of components for gas tanks using HDPE (High-Density Polyethylene) plastic. This case study explores the internal components we produced, which include floaters and wiring attachments. These components are crucial for maintaining stable fuel levels within the tank, ensuring optimal vehicle handling even during sudden braking. The use of HDPE, an upgraded blow molding material, enables us to create intricate geometries that facilitate controlled fuel flow. Additionally, Our collaboration with the gas tank manufacturer focuses on compatibility and recyclability, leading to the utilization of blow-molding grade material in an injection molding process.

Customer Requirements

The primary customer for these internal components is the gas tank manufacturer, who subsequently supplies them to automakers. The customer’s requirements center around two key aspects. Firstly, the product must be compatible with their tank, as the plastic components are welded to the tank structure. Secondly, the entire product should be easily recyclable without significant manipulation or disassembly. Therefore, we must use the same material as the customer, which necessitates working with blow-molding grade HDPE in an injection molding machine.

Enhancing Fuel Stability and Handling

By employing HDPE plastic, Penne ensures that their internal components offer optimal fuel stability and improved vehicle handling. The components consist of a series of perforated baffles that allow fuel to pass through gently, preventing excessive volume fluctuations during abrupt braking or other sudden movements. The baffles efficiently distribute the fuel against the perforated surfaces, facilitating a controlled flow that minimizes the impact on the vehicle’s handling characteristics. The geometrical complexity of the HDPE plastic components enhances their effectiveness, providing an ideal solution for maintaining fuel stability.

Collaboration for Compatibility and Recyclability

Our collaboration with the gas tank manufacturer emphasizes the importance of compatibility and recyclability. By utilizing the blow-molding grade HDPE material, we ensure compatibility with the tank’s structure, enabling effective welding and seamless integration of the internal components. The injection molding process employed by us, though typically associated with thicker walls, achieves the desired geometries and intricate designs demanded by the gas tank manufacturer.

Moreover, the choice of HDPE plastic facilitates easy recyclability of the entire product. The ability to recycle the entire component without extensive manipulation or disassembly streamlines the recycling process, reducing environmental impact and promoting circular economy principles.

Overcoming Material Challenges

Adapting blow-molding grade HDPE for injection molding presented a significant challenge for us. The material characteristics of blow-molding grade HDPE differ from those typically used in injection molding processes. However, our expertise in injection molding enables us to overcome this challenge. By meticulously fine-tuning the injection molding machine’s settings and adjusting process parameters, we successfully maintain the desired material properties and geometry of the requested components. The combination of blow-molding grade HDPE and injection molding expertise ensures the production of high-quality internals that meet the customer’s specifications.


Penne NV’s expertise in manufacturing HDPE plastic components for gas tank internals showcases their commitment to delivering innovative solutions. By utilizing upgraded blow-molding grade HDPE in an injection molding process, we achieved optimal fuel stability, enabling vehicles to maintain their handling characteristics even during abrupt braking or sudden movements. The collaboration with the gas tank manufacturer ensures compatibility and recyclability, with the entire component being easily recyclable without extensive manipulation. Our ability to overcome the challenges of using blow-molding grade HDPE in injection molding highlights our dedication to meeting customer requirements and producing highly complex components with exceptional precision and functionality.

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