Periodic Reporting for period 2 - CREATE (Creating Artificial Turf (AT) Yarns with New Recycling Technologies for Circular Economy)
Reporting period: 2021-10-01 to 2024-03-31
Re-Match was founded with the ambition of setting a new global standard in recycling artificial turf (AT) while protecting the environment. Our goal is to develop a sustainable, transparent, and proven solution that promotes a full circular economy by upcycling every AT component. To achieve a complete recycling cycle of used ATs, Re-Match has developed a groundbreaking patented process that combines state-of-the-art technologies, adding the missing link to complete the upcycling of the plastic component.
The final step in closing the loop in the recycling process is to create a method for reusing the polyolefin fraction from the Re-Match facility (i.e. the recycled artificial turf yarn/fiber) for yarns in new AT – cradle-to-cradle recycling. This process aims to reuse the materials in products within our industry and provide an option to sell to other industries, as long as virgin raw materials are replaced.
Before the project started, physical separation of AT components was possible, but creating new yarn from the recycled polyolefin fraction was not feasible due to contamination with at least three different non-polyolefin-based products. Alternative cleaning methods, such as water-based solutions or chemical recycling, have proved insufficient or not viable.
With the conclusion of project CREATE, Re-Match has successfully developed, patented, and validated a method for recycling artificial turf to produce new artificial turf yarn, achieving the project's overall objective. Using this method, Re-Match has initiated the production, installation, and validation of four full-size test pitches in collaboration with the Victoria Group - one of the largest artificial turf producers in the world. The first test pitch has been successfully installed, while the material for the remaining three pitches has been produced. The final installation activities will be concluded in the summer of 2024. We have protected our process with patents and are focusing on marketing this innovation - the key element in recycling and subsequent extrusion of artificial turf yarns - together with Victoria Group, with whom we have launched a large marketing campaign. Their commitment showcases the strong future commercial expectations of the project's results.
Re-Match has also achieved several certifications throughout the project's lifetime, including ISO 9001, ISO 14001, EuCertPlast, and ISCC+, emphasizing the quality, transparency, and sustainability of Re-Match's recycling and production methods.
The final step in closing the loop in the recycling process is to create a method for reusing the polyolefin fraction from the Re-Match facility (i.e. the recycled artificial turf yarn/fiber) for yarns in new AT – cradle-to-cradle recycling. This process aims to reuse the materials in products within our industry and provide an option to sell to other industries, as long as virgin raw materials are replaced.
Before the project started, physical separation of AT components was possible, but creating new yarn from the recycled polyolefin fraction was not feasible due to contamination with at least three different non-polyolefin-based products. Alternative cleaning methods, such as water-based solutions or chemical recycling, have proved insufficient or not viable.
With the conclusion of project CREATE, Re-Match has successfully developed, patented, and validated a method for recycling artificial turf to produce new artificial turf yarn, achieving the project's overall objective. Using this method, Re-Match has initiated the production, installation, and validation of four full-size test pitches in collaboration with the Victoria Group - one of the largest artificial turf producers in the world. The first test pitch has been successfully installed, while the material for the remaining three pitches has been produced. The final installation activities will be concluded in the summer of 2024. We have protected our process with patents and are focusing on marketing this innovation - the key element in recycling and subsequent extrusion of artificial turf yarns - together with Victoria Group, with whom we have launched a large marketing campaign. Their commitment showcases the strong future commercial expectations of the project's results.
Re-Match has also achieved several certifications throughout the project's lifetime, including ISO 9001, ISO 14001, EuCertPlast, and ISCC+, emphasizing the quality, transparency, and sustainability of Re-Match's recycling and production methods.
Original Proposed Solution
The CreaSolv Process, a solution developed and patented by the Fraunhofer Institute in Germany, was initially planned for recycling and reusing the polyolefin volume. An NDA agreement was signed between the Fraunhofer Institute and Re-Match, and the first tests were conducted in Q2 and Q3 2021. The polyolefin fraction from the Re-Match factory in Herning was used as input for the CreaSolv process, with the goal of producing reprocessed polyolefins. However, because the polyolefin fraction from the Re-Match factory was not pure enough, alternative technologies to improve the quality of the polyolefins were investigated. These included washing, agglomerating, and re-extruding the polyolefin product prior to being used as input for the CreaSolv process. This enabled a better CreaSolv process with higher yield and fewer costs. The resulting product was sampled with potential customers to evaluate the feasibility of replacing virgin raw materials with up to 30% (or higher – up to 100%) recycled materials, as prescribed by the European Green Deal by 2025.
Revised Solution (Second Route to Market)
The initial objective was to use the CreaSolv process to create a renewed polyolefin fraction for use in AT production. However, after trials and more test data became available, a financial feasibility study showed that this was not attractive, as the costs for a full-scale plant and its operation would make the product too expensive.
During the process of cleaning the Re-Match polyolefins, Re-Match developed a second route to market in 2023, creating pure "Re-Match Polyolefins" without using the CreaSolv patent. This solution, called the Fine-Dust-Cleaning system (FDC process), has been very successful. As of March 1st, 2024, Re-Match and its partners have closed the loop in recycling, producing yarns with 50% recycled content. This new solution achieves a higher percentage of recycled materials than the initial goal and lowers the costs for both machine installation and ongoing operations, making the product profitable at market rates for virgin products.
Demonstration, Certification, and Dissemination
During the development of the FDC process, Re-Match received many orders for new installations using the recycled artificial turf fibers (polyolefins), with several installations already completed this year. This outcome will significantly impact not only our industry but the entire recycling industry, as the method developed by Re-Match becomes a realistic option for creating renewed polyolefins.
Throughout the project, an objective has been to document all steps in the process and achieve certification. This work started with setting up our QMS and EMS system and subsequently obtaining ISO 9001 and 14001 certifications. Furthermore, we achieved ISCC+ certification and conducted KIWA ISA studies on the products developed in the project.
Re-Match has invested considerable time and effort in demonstrating the potential to the industry and future customers by inviting them to see our state-of-the-art factory in Tiel, The Netherlands, and presenting our ongoing results at various exhibitions, conference and trade fairs. This has generated significant interest in the clean polyolefins fraction and carpets made from worn-out AT.
Overall, we are pleased to report that the grant from EU Horizon has enabled Re-Match to develop a cradle-to-cradle solution that is now proven both commercially and financially attractive. We expect to continue delivering more and more worn-out AT polyolefins to turf manufacturers over the next few years, thereby making the entire industry circular.
The CreaSolv Process, a solution developed and patented by the Fraunhofer Institute in Germany, was initially planned for recycling and reusing the polyolefin volume. An NDA agreement was signed between the Fraunhofer Institute and Re-Match, and the first tests were conducted in Q2 and Q3 2021. The polyolefin fraction from the Re-Match factory in Herning was used as input for the CreaSolv process, with the goal of producing reprocessed polyolefins. However, because the polyolefin fraction from the Re-Match factory was not pure enough, alternative technologies to improve the quality of the polyolefins were investigated. These included washing, agglomerating, and re-extruding the polyolefin product prior to being used as input for the CreaSolv process. This enabled a better CreaSolv process with higher yield and fewer costs. The resulting product was sampled with potential customers to evaluate the feasibility of replacing virgin raw materials with up to 30% (or higher – up to 100%) recycled materials, as prescribed by the European Green Deal by 2025.
Revised Solution (Second Route to Market)
The initial objective was to use the CreaSolv process to create a renewed polyolefin fraction for use in AT production. However, after trials and more test data became available, a financial feasibility study showed that this was not attractive, as the costs for a full-scale plant and its operation would make the product too expensive.
During the process of cleaning the Re-Match polyolefins, Re-Match developed a second route to market in 2023, creating pure "Re-Match Polyolefins" without using the CreaSolv patent. This solution, called the Fine-Dust-Cleaning system (FDC process), has been very successful. As of March 1st, 2024, Re-Match and its partners have closed the loop in recycling, producing yarns with 50% recycled content. This new solution achieves a higher percentage of recycled materials than the initial goal and lowers the costs for both machine installation and ongoing operations, making the product profitable at market rates for virgin products.
Demonstration, Certification, and Dissemination
During the development of the FDC process, Re-Match received many orders for new installations using the recycled artificial turf fibers (polyolefins), with several installations already completed this year. This outcome will significantly impact not only our industry but the entire recycling industry, as the method developed by Re-Match becomes a realistic option for creating renewed polyolefins.
Throughout the project, an objective has been to document all steps in the process and achieve certification. This work started with setting up our QMS and EMS system and subsequently obtaining ISO 9001 and 14001 certifications. Furthermore, we achieved ISCC+ certification and conducted KIWA ISA studies on the products developed in the project.
Re-Match has invested considerable time and effort in demonstrating the potential to the industry and future customers by inviting them to see our state-of-the-art factory in Tiel, The Netherlands, and presenting our ongoing results at various exhibitions, conference and trade fairs. This has generated significant interest in the clean polyolefins fraction and carpets made from worn-out AT.
Overall, we are pleased to report that the grant from EU Horizon has enabled Re-Match to develop a cradle-to-cradle solution that is now proven both commercially and financially attractive. We expect to continue delivering more and more worn-out AT polyolefins to turf manufacturers over the next few years, thereby making the entire industry circular.
In recent years, the circular economy has gained increasing prominence as a tool for addressing some of the world's most pressing sustainable development (SD) challenges. By tackling root causes, Re-Match’s circular economy concept—a system in which plastic waste and pollution are designed out, materials are kept in use, and natural systems are preserved—offers a ground-breaking approach within the AT upcycling segment. This approach further accelerates the implementation of the 2030 Agenda for Sustainable Development. Moreover, our circular model for ATs holds significant promise for achieving multiple Sustainable Development Goals (SDGs), including those related to economic growth and sustainable consumption and production.
Due to the negative environmental impact of traditional AT pitches, environmental concerns are driving the demand for more sustainable solutions like those developed by Re-Match. This shift aligns with broader global efforts to promote sustainability and reduce the carbon footprint of various industries, including sports and recreation. The CREATE project positions Re-Match at the forefront of these efforts, offering a viable and economically attractive alternative to conventional AT solutions.
Due to the negative environmental impact of traditional AT pitches, environmental concerns are driving the demand for more sustainable solutions like those developed by Re-Match. This shift aligns with broader global efforts to promote sustainability and reduce the carbon footprint of various industries, including sports and recreation. The CREATE project positions Re-Match at the forefront of these efforts, offering a viable and economically attractive alternative to conventional AT solutions.