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.
