Posted on 12th May 2026 by Penny Gibbs
Open process tanks create unavoidable losses in chemical processing and electroplating plants. Heat escapes from the liquid surface, vapour and fumes affect the workplace, and evaporation can drive ongoing chemical loss. Over time, these factors can increase operating costs, make temperature control harder, and reduce comfort for operators.
Croffles offer a straightforward approach to these challenges. They form a flexible floating cover across the surface of process tanks, helping reduce heat loss, fumes and evaporation while supporting more stable working conditions.
Croffles are hollow plastic balls that float on the surface of open chemical tanks. When applied as a “blanket” across the liquid, they create a flexible cover that moves naturally with the process, rather than relying on rigid lids or permanent structures.
Euro-Matic has produced croffles since 1965 and supplies them globally for industrial use. They are widely used in manufacturing settings where open tanks are part of day-to-day operations.
In chemical processing, electroplating, anodising and galvanising, open tanks are often essential. They can also introduce a number of knock-on effects, including:
Croffles address these issues at the surface by reducing direct exposure of the liquid to surrounding air.
When croffles cover the surface of a tank, they help reduce the main pathways of loss.
By covering the liquid surface, croffles reduce heat escaping into the surrounding air. Benefits are often quoted as saving up to 75% on heating costs or energy bills, depending on application.
A covered surface reduces evaporation from the tank by 90% – which also supports lower chemical loss in open processes Fewer fumes and improved air quality
By reducing the exposed surface area, croffles help cut fumes and odour at source. This supports more comfortable working conditions and improved air quality around process areas.
Industrial tanks vary widely, and material compatibility matters. Croffles are available in plastics such as HDPE and commonly PP, selected based on the chemicals involved and the temperatures they need to withstand. They also come in a broad range of sizes, from 6mm up to 150mm, allowing them to be matched to different tank designs and operating requirements.
A practical advantage is that croffles sit on the surface and move around components within the tank area. Once in place, the balls require no maintenance, and installation is straightforward as the balls are simply added to the tank to form the surface cover.
Croffles are used across a wide range of industrial settings, including:
They are particularly relevant anywhere open tanks are contributing to energy loss, evaporation, chemical loss or fume management challenges.
Many sites assume they need complex extraction changes, structural covers or significant engineering work to reduce evaporation and fumes. Croffles offer an alternative route: a flexible floating cover that targets the source of loss with minimal disruption.
For businesses reviewing energy use, workplace comfort, or chemical loss from open tanks, croffles are a practical option to assess as part of wider operational improvement.
To support early planning, Euro-Matic’s Ball Calculator can help estimate quantities based on tank dimensions.
