A close collaboration with Schramm, United Works and Re-Match has resulted in Edel Grass being the first manufacturer in the world to produce artificial turf for sports with materials derived from end-of-life-turf. The Environmental Cost Indicator (ECI), including the CO2-footprint of their Edel Athmos with an Edel Xero coating, already shows a 43.3% reduction, compared to a compatible product made of virgin materials. Extensive testing by a FIFA accredited laboratory has shown that it is superior in performance.
The achievement proves that meeting the sustainable development goals set by the European Commission is already well-advanced on the path to becoming achievable well-before the first deadline set by the authorities of a 55% plastic waste reduction by 2030. By 2050, this volume should be up to 100%. This is to close the recycling loop. “It is an ambition the artificial turf industry has been pursuing for many years, as there is a consensus that incinerating end-of-life turf is not the way forward,” says Victoria Grass Group CEO, Davida Decorte. Edel Grass is part of this group. She detests the CO2 emissions that this leaves the world with. “Closing the recycling loop is a responsibility that falls on our shoulders as an industry and certainly on us as a group. Succeeding in doing so is our strength and very promising for our collective future.”
Taking a giant leap
While repurposing end-of-life turf to other products like picnic benches or shore protection was already a step forward, the ability to produce new high-end artificial turf carpets to facilitate sports means that a giant leap has been taken. Edel Grass Head of R&D, Frank Pfeiffer explains. “The idea was explored by several companies for a number of years before they eventually abandoned it from fear that impurity in the compound would hamper a smooth production of artificial turf yarns. Together with sister companies Schramm, United Works and third-party artificial turf recycling company Re-Match, we decided to continue researching it. Given the fact that the carpet we have now produced passed 15,000 cycles on the Lisport XL-test, I can confidently say that we have succeeded.” 15,000 cycles is double the amount FIFA demands to establish the longevity of artificial turf carpets for its quality turf programme.
Dual fibre
The Edel Athmos is a dual-fibre that has a core of recycled end-of-life turf and a virgin polyethylene sheet. “At present, half of the yarn is made of reclaimed materials but we are already exploring ways to increase that volume,” Pfeiffer continues. The high criteria FIFA, World Rugby, the International Hockey Federation (FIH) and other (international) sports governing bodies have set for artificial yarns for sports currently make it impossible to produce the entire fibre from end-of-life turf. “We still have to add UV-stabilizers and other additives to ensure the yarn will pass the compulsory performance and durability tests,” Pfeiffer points out. Nevertheless, he believes it is only a matter of time before the entire yarn can be made of reclaimed end-of-life turf. “Technologies to separate the various components in end-of-life turf are increasingly becoming more sophisticated as is the machinery to produce yarns for synthetic turf. We continue to closely monitor these developments.”
Improved coating
The sustainability benefits of the Edel Athmos yarns are complemented by the Edel Xero coating. This water-based disperse contains a secret ingredient that is also sourced from recycled end-of-life turf. “The polyethylene final product is stiffer but more stable than latex coating. Also, it delivers a better tuftlock and dimensional stability to the carpet.” Pfeiffer points out that, in addition to the coating quality, the consortium has also worked on the processability of the material. “As this coating is a new product, we have to make sure that installing companies can keep working with their known and most-used glues when installing an artificial turf field. Currently, a first commonly used glue is tested and approved, but it is to be expected that other types will be available soon.”
Pfeiffer too hails the additional environmental savings by the final artificial turf product. “The new coating process requires significantly less water compared to what is needed when coating with latex. This also saves us on energy as we do not have to evaporate as much water as is necessary in a traditional coating process.” Research shows that the ECI (including CO2 emission) as part of the Life-Cycle Analysis (LCA) saved can be as much as 43,3% compared to a traditional turf system life cycle process.
A new approach to recycling
Key to all this, is the quality control process that artificial turf recycling company Re-Match adheres to when processing end-of-life turf. “Every shipment we get is first subjected to a Differential Scanning Calorimetry (DSC) test to meticulously establish the quality of the various products that made up the artificial turf system we are supposed to process,” Re-Match founder Dennis Andersen explains. This is why he considers Re-Match as not just a recycler, but more of a raw material broker. “We go as far as identifying the precise polymer quality that was used to produce the yarns.” The way Re-Match processes the turf, the detailed documenting of the process, and the fact that the feedstock is processed in batches, sets Re-Match apart from other recyclers. “We know exactly when and where the end-of-life turf we have accepted, is in our supply chain. We can prove to the supplier that it is processed timeously and according to what we promised. All this is captured on the certificate we send them upon finalization of the process.” This also allows Re-Match to precisely supply the quality their customers for reclaimed materials are looking for.
Improved separation process
All came together when Re-Match installed a new fine dust filtering system at its latest plant. “As we are on an ambitious roll-out to build artificial turf recycling plants around the world, we are continually reviewing the equipment we use at our existing sites and looking for ways to further improve the process or final product in an upcoming plant.” With currently three plants up and running and close to 10 in the pipeline, Andersen is confident that this parallel process will continue improving the purity of the components they supply to the Victoria Grass Group.
Landscaping next?
Davida Decorte believes that a further improved separation process could add value to other companies in the group too. “This could see us also producing the very thin yarns used in landscaping products.” It is something that is already being tested. She points out that Victoria Grass Group company Royal Grass, the company that was the first ever to develop high-end artificial turf specifically for use in landscaping projects, was also the first to sign an agreement with Re-Match to collect and process landscaping turf. “Since our start in 2003, we believe that it is important to offer our customers the opportunity to return used artificial grass, so the material can be reused in an environmentally-friendly way instead of ending up on the plastic waste mountain. This is not a choice, but our obligation,” Royal Grass founder, Freek Verhoeven said in 2018 when he signed the agreement.
Enough raw materials
The production of artificial turf for sports requires a constant supply of raw materials of a consistent quality. “Even though both the virgin and reclaimed polymers are a polyethylene, the window to merge them correctly is very thin, or else they will delaminate, as was witnessed by the companies who eventually abandoned the idea of combining a virgin with a reclaimed polymer,” Pfeiffer points out. Also artificial turf products for sports have to meet very high standards, and the quality of the raw materials used is documented. “Every new carpet from that product category has to be exactly the same as what the sports governing bodies established prior to giving their approval to Edel Grass to market it.” In order to guarantee it can do so, Victoria Grass Group has signed an exclusive agreement with Re-Match for obtaining the materials. Dennis Andersen confidently states that there is enough to meet demand for artificial turf made with reclaimed end-of-life turf components. “There is enough supply of end-of-life turf around the world already that is currently waiting to be processed. In the coming years, this volume will go up even further, as a growing number of artificial turf installations will have to be renovated,” he assures. This is why Edel Grass is already exploring new introductions. “We are already looking at using this technique to produce artificial turf carpets for non-filled systems for football or dry-turf carpets for hockey,” Pfeiffer says, referring to two of the artificial turf developments that have been identified as being the future for the respective sports. “The Victoria Grass Group is always exploring ideas and solutions to close the loop and to reduce waste. Using a raw material from end-of-life turf is an exciting development that further adds value to being truly unique,” Davida Decorte concludes.