Specialists in Bespoke Solutions

How-To: Make a Float Switch - Injection Moulding Process

Injection moulding machinery.

T-T Controls FLO range of float switches offers reliable level control, floating on the surface of a liquid and starting/stopping equipment such as a pump or valve when the liquid reaches predetermined levels.

Have you ever wondered how they are made? Read on for a quick insight into the moulding process that goes into making our renowned FLO range, designed from our six decades of experience in pump design and fluid handling.


Each float switch in the range has been manufactured with a high-quality polypropylene housing, offering superior strength and durability.

The injection moulding process involves drying plastic pellets to remove excess moisture, which is then passed through the machine and heated to melt the plastic so that it can be ‘shot’ via a rotating screw mechanism into the tooling mould specifically designed to our specifications.

Finally, the product is ejected and cooled prior to a final quality check. The image below shows a PDF electronic work instruction that the machine operator adheres to and can use for quality assurance to ensure the products are made using the latest instructions.

After the injection moulding process is complete, the shells are then used to encompass premanufactured cable assemblies.

What Is a Float Switch?

As their name suggests, a float switch is a simple device that floats on top of a liquid, moving up and down with the liquid and operating an electrical microswitch, which is used to switch the attached component (e.g. a pump, valve or alarm) on and off when it reaches a certain predetermined level.

For more information on float switches and how they work. please see our article here.

FLO Range: Float Switches for Every Application

T-T offers a wide range of float switches in our FLO Series, with options for every application. Each model offers superior build quality, being proven to meet the many demands encountered in liquid control.

  • FLO101 - for zone 0 applications and low current switching
  • FLO102 - general purpose float switch
  • FLO106 - for diesel and fuel oils
  • FLO107 - for potable and drinking water applications

Not sure which one is right for you? For expert advice on choosing the best float switch for your application, call our experts on +44 (0)1630 647200, email ttcontrols@ttpumps.com or fill in our online enquiry form.

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