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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 modeling 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 is 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 center 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 focuses further on providing additional functionalities 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 product uses. With over 500 models, we offer the largest range of products in all of Europe and America.

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 apply 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.

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 recognized 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, digitized, 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 is 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.

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