Sekisui Alveo introduces innovative shockpad foam for non-infill systems

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Sekisui Alveo, European manufacturer of high-quality polyolefin foams, has expanded its well-known Alveosport product line. Alveosport NUT 3011-14 is a new foam designed especially for use as a shockpad in artificial turf systems designed without infill. The innovative material not only meets the technical and quality requirements for sports fields, it presents an alternative to the questionable rubber infill used in many artificial turf systems.

Various artificial turf systems in use today incorporate rubber infill in order to achieve the desired performance characteristics. Problem is, this ground rubber is a material of concern. It impacts both the environmental and health, and this has been a topic of discussion at the European level. Artificial turf systems designed without the infill appear to be a promising alternative.

New shockpad with enhanced performance

In artificial turf systems without infill, more of the vertical sports performance must be provided by the substructure. The shockpad beneath the artificial turf carpet must be designed for this purpose. Alveosport NUT 3011-14 is a new product specially developed to meet these technical requirements. The chemical composition, in combination with the physical design of the shockpad, results in an excellent balance of shock absorption, vertical deformation, and ball bounce – directly after installation as well as throughout the lifetime of the turf system.

Pioneering installations

Alveosport NUT 3011-14 was used in a new non-infill football turf built this year for DSV Concordia in Delft, the Netherlands. In this system, FieldTurf Ultra 360 non-infill carpet is installed over the shockpad. Rob Heusinkveld, Product Manager at FieldTurf Tarkett Benelux, explains the design: “This system is a real further development in the field of non-infill synthetic turf systems. Because there is no performance infill, most of the performance properties have to be provided by the shockpad. Alveosport is our go-to shockpad for synthetic systems because of its proven technical performance – so Alveosport NUT 3011-14, developed especially for use in non-infill systems, was an obvious choice for this turf.” In addition to this example, four non-infill synthetic turf fields based on Alveosport NUT 3011-14 were successfully installed in Norway last year.

Technical development

These pioneering installations as well as recent studies indicate that by optimizing test methods and standards, non-infill systems will be able to fully meet players’ expectations and the technical requirements of FIFA and other organisations. When this happens, non-infill systems are expected to become a high-performance alternative to football turf systems using performance infill. Sliding performance and shoe grip remain key points of attention as non-infill systems develop. As more clubs opt for non-infill systems, acceptance will grow and the system and components will be further developed. Sekisui Alveo’s leadership role in this trend towards healthier artificial turf systems is fully in line with the company’s mission of Innovation in Foam.

Alveosport: an all-round winner

In terms of installation, technical performance, and environmental impact, Alveosport is an all-round winner. Installing the shockpad is quick and easy. It can be done in one day under any weather conditions and requires neither special machinery nor skilled personnel. The cushioning significantly reduces the risk of injuries. In terms of environmental performance, Alveosport releases no harmful chemicals or gases known to pollute soil, water, or air.
Artificial turf systems without infill are even quicker to install, easier to maintain, and ultimately easier to recycle at the end of their service life.

Sound long-term investment

In many cases, the Alveosport shockpad can be reused when a field is being renovated. When the artificial turf wears out after a number of years, the owner only needs to invest in a new carpet. This saves significant costs. It also saves time, energy, and material – and minimizes the interruption so the players can return to a comfortable, healthy, high-performance field within a very short time.

Sport Group recycles synthetic turf in the future

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The Sport Group is one of the world’s leading companies in the field of synthetic sports surfaces. With its subsidiary Polytan, the company has a high market share in the construction of artificial turf pitches and running tracks. Now the Bavarian company is also entering the recycling business. The newly founded subsidiary FormaTurf will turn old artificial turf pitches into new products starting next year.
Frank Dittrich, CEO of the Sport Group: “This makes us the only company in our industry to cover the entire artificial turf value chain and close the loop. We develop, we produce, we install, we maintain, we remove and we recycle”. The special thing: FormaTurf recycles almost 100 percent of an old artificial turf pitch consisting of the turf carpet, sand and rubber granulate. “We do not see an old artificial turf as garbage, but as a valuable raw material”, continues Frank Dittrich. The aim of FormaTurf is to turn the old material into new, durable products. To this end the company is building a new factory in Germany.
In recent years the number of artificial turf pitches in Germany has increased significantly. The service life of the upper layer (lawn carpet, sand, infill granulate) of a pitch is normally between ten and fifteen years. Many pitches have now reached the end of their lifetime or will reach it in the coming years. For this reason, FormaTurf anticipates a sharp increase in the number of recyclable artificial turf pitches in the coming years. This means that large quantities of synthetic material are returning to the resource cycle and can be recycled sensibly. FormaTurf can recycle almost all installed artificial turf systems and is not limited to taking back pitches installed by the Sport Group subsidiary Polytan.
The creation of FormaTurf is another of many steps in the Sport Group’s sustainability strategy. Through its subsidiary Polytan, for example, the company offers the first CO2-neutral artificial turf made of renewable raw materials. “We want to be the most sustainable company in our industry. We could not close our eyes to the issue of recycling. I am convinced that our overall concept offers the customer the best possible solution,” says Frank Dittrich.

Risk minimization by irradiation to ultraviolet light

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Recreational Systems International can confirm that its Rhenac Sports LED UV-C 600 technology is effective in disinfecting lawns.

The mobile RHENAC UVC 600 lawn disinfector has been used for years to prevent the development of algae, fungi and other lawn diseases on sports turf. The system is working with UVC light, which is fundamentally suitable for combating viruses and bacteria and has similarly been used successfully for a long time for disinfecting surfaces and objects in hospitals. UVC light in the spectral range from 100 to 280 nm is the short-wave range of ultraviolet light. By irradiation with this very high-energy light, a photochemical reaction is triggered, which can contribute to the targeted damage or killing of microorganisms.

The RHENAC UVC lawn disinfector is moved across the sports surface using a lawn tractor. “Since the effectiveness of UVC light when deactivating microorganisms depends on the dosage, the light intensity and the light spectrum must be set according to our specifications when treating the lawn”, says Arnoud Fiolet from RHENAC GreenTec AG. With the RHENAC system, natural grass, hybrid and artificial grass pitches can be treated without affecting the quality of the lawn. “Numerous scientific studies have confirmed that UVC light can also be used to combat viruses. The treatment of the sports surfaces by our system thus contributes significantly to minimizing risk, ”says Fiolet.

RSI welcomes Markus Deimling

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Recreational Systems International (RSI) has strengthened its LED Grass Grow technology for sports fields team in Germany by appointing Markus Deimling as new business manager for stadium pitch concepts . Deimling brings with close to 30 years’ experience in the flooring industry.

The appointment of a Business Manager Stadium Pitch Concepts for the German speaking countries is the final step for the launch of  the revolutionary Rhenac Sports LED grass grow unit later this year. The fully-automated unit for a full-size football pitch is currently being installed at the Bundesliga club FC Schalke 04. The system can be integrated in any stadium and uses various resources to decide on the best treatment for the pitch. Once this has been determined, it automatically instructs the unit to adjust the light, heat, fertilizing, irrigation or oxygen treatment.

“The launch of this technology is highly anticipated by clubs and stadiums all over the world as our integrated approach and unique knowledge regarding the perfect growth and recuperation conditions for a grass pitch, is being viewed as the final step towards a perfect pitch. With the first unit being unveiled in Germany later this year, the appointment of a country manager will help us rolling out the technology in one of Europe’s main football leagues,” says RSI Partner Arnoud Fiolet.

RSI is very pleased that Markus Deimling will be starting the position. Deimling has been in the flooring industry for close to 30 years and is well-known by the German sports venue fraternity. To him the new position is a logical step to align his ambitions with the latest market trend and preferences.

“Delivering the best quality surface has been my focus throughout my career and the current trend for stadiums is to have a grass or hybrid pitch. As Country Manager for RSI I will be in the position to draw from the best minds and scientists available to determine the best treatment for grass pitches and to deliver the latest and smart technology to have this achieved. ”

The appointment will be effective 1 February 2020.

RSI wins innovation tender; 100% recyclable artifical turf in the making

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Dutch government tasks Recreational Systems International (RSI) with developing a truly 100% circular artificial turf.

RSI has won a tender by the Dutch government to develop the artificial turf systems of the future. The new systems will be 100% recyclable, while also meeting the quality standards defined in the Quality Programmes issued by FIFA, World Rugby and FIH.  

The Dutch Ministry of Health, Welfare and Sport (VWS) published a tender for ‘sustainable sports fields’ earlier this year. Together with its consortium partners DSM-NIAGA and NEXTECONOMY, RSI submitted a proposal for introducing a new raw material that will revolutionize the artificial turf industry, reflecting their a zero waste philosophy.

“We will introduce a compound that will be stronger than the polypropylene that is currently used for the backing, that is as friendly to the skin as the polyethylene currently used for the fibers, and that is as secure as the latex currently used for fixing the fibres to the backing,” says Arnoud Fiolet of Recreational Systems International (RSI).  

Furthermore, the RSI Monomere concept project will deliver an artificial turf field that can easily be recycled into a new artificial turf field at the end of its economic lifespan. “It will be much easier to recycle an artificial turf field when it is made of just one high-end and non-degenerative material. At the end of its lifespan it will be possible to convert the recovered material into granules that can be used to manufacture artificial turf again. The product will become a truly 100% circular product as the material we will use does not degenerate,” he adds. 

The polypropylene, polyethylene and latex currently used in most artificial turf systems are degenerative materials that are difficult to separate. The materials cannot be mixed when producing new high-end products. 

Owners of artificial turf in most countries in Europe are left with no other option than to send the old turf to landfills or incinerators which results in unnecessary CO2 emissions. In the few countries where a recycling industry for artificial turf exists, the materials can only be used for  the production of lower-quality products such as picnic benches and kick boards. This problem is exacerbated by the absence of technology that allows for artificial turf to be recycled in artificial turf. 

Follow-up

In June this year, RSI and its consortium partners was one of the few organizations that were awarded funds by the Dutch government to do a feasibility study into solutions for ‘more sustainable sports fields’. 

“It is a challenging quest to ensure that we are going to get artificial turf systems that meet all the strict requirements of clubs, players and the governing bodies without compromising on the quality and durability of an artificial turf system. That is why RSI will continue collaborating closely in this research with the various suppliers of raw materials, researchers and other specialists who focus on the quality of artificial turf.”

As well as adhering to the stringent quality requirements dictated by the various stakeholders, RSI and the consortium partners will also pursue introducing a product that is affordable to any club or school that is keen to have an artificial turf surface. 

“RSI and its consortium partners strive day in, day out to deliver reliable, sustainable and innovative sports fields. The confidence shown by the Ministry of Health, Welfare and Sport therefore stimulates us even more to achieve a good result,” concludes Fiolet.

The first CO2-neutral football turf

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LigaTurf Cross GT synthetic turf made from bio-based plastic

The first CO2-neutral football turf

The LigaTurf Cross football turf has become an absolute model of success since it was launched on the market. The high demand it enjoys can be attributed to the special combination of smooth and textured synthetic turf fibres in one system. Not only does this give the sports surface natural playing properties, it is also robust and easy to maintain. For FSB 2019 in Cologne, Polytan has taken the turf another logical step further, adding the component of sustainability. The fibres of the new LigaTurf Cross GT consist to 80% of bio-based PE plastic. That, along with additional in-process measures, have made it the first CO2-neutral synthetic football turf in the world.

The bio-based plastic used for the new LigaTurf Cross GT is called I’m greenTM polyethylene and is manufactured by the Brazilian world market leader, Braskem. It is extracted from sugar cane, a renewable raw material, far from the Amazon region. Another decisive environmental aspect for Polytan is that the sugar cane is cultivated first and foremost for the production of food: only the third pressing, which can no longer be used for table sugar, is used to manufacture the bioplastic.

Polytan is currently producing the fibres for the LigaTurf Cross GT synthetic turf from I’m greenTM polyethylene – accounting for a share of up to 80%. That ensures the optimum environmental balance, because this bio-based raw material allows more than 2 metric tons of CO2 to be saved for every ton of material that is used for the fibre filaments. Over a complete football pitch, this adds up to about 56 tons of CO2. This is the basis for the CO2 neutrality of the new LigaTurf Cross CT. It is ultimately achieved thanks to a whole raft of measures introduced by Polytan, including switching the entire production in Gefrath over to 100% green electricity and optimising the manufacture of the back coating of the synthetic turf.

This CO2-neutral eco-balance of the LigaTurf Cross GT enhances the attractiveness of the synthetic turf for clubs and local authorities still further, because in addition to the high player comfort delivered by the smooth filaments and the extremely hard-wearing and easy-to-maintain properties of the textured filaments, it also meets high environmental standards. And as if that were not enough, the special combination of fibres allows the quantity of infill crumb to be reduced by another 40 per cent or so to less than 2 kg/m². What is more, the higher stitch density ensures better retention of the crumb in the surface, optimises player protection and reduces the unwanted splash effect.

Friedemann Söll, Polytan Chief Product Officer Region EMEA, on the innovation presented in Cologne: “LigaTurf Cross GT, the world’s first CO2-neutral football turf, is already the fourth product in the Green Technology range we launched in 2017. All GT product innovations are characterised by an improved eco-balance in the manufacturing process and can be easily recycled at a later stage.” The bio-based I’m greenTM polyethylene from Braskem has already proven its worth in the Poligras Tokyo GT hockey turf, the fibres of which are likewise made from this raw material. The hockey surface was developed with an eye on the 2020 Olympic Games in Tokyo, where it supports the aim of being the first CO2-neutral Olympic Games.

High-tech sports surfaces made from sus-tainable raw materials

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Polytan presented Green Technology at FSB 2019

High-tech sports surfaces made from sustainable raw materials

How sustainable can modern high-tech sports surfaces made from synthetic material get? Polytan gave the answer to that question at this year’s FSB in Cologne, the leading international trade fair for public space, sports and leisure facilities. There the Burgheim-based sports surface specialist presented four innovations from its Green Technology initiative, which includes both products and services. It has given rise to a new product line that features particularly eco-friendly sports surfaces.

Climate change, microplastics, particulates and pollutant emissions – these are the issues that will occupy us now and in the future. How we deal with them is an even greater challenge for companies that process plastics than for manufacturers in other industries.

Polytan is facing up to this responsibility: two years ago, it launched the Green Technology product range, which features particularly sustainable products. All life cycle phases of a product are taken into consideration – from selection of the raw material through production, installation, use and maintenance all the way to disposal and recycling. The aim is to supplement the product range step by step with environmentally-compatible innovations and move over entirely to Green Technology in the long term, but without having to suffer any loss of quality in terms of the performance and long life of the synthetic turf systems, tartan tracks and soft-impact surfaces.

Natural raw materials and CO2-reducing manufacturing processes

The good environmental balance of the sports surfaces from the Green Technology range is founded on bio-based plastics that are obtained from sustainable agriculture, rapidly renewable natural raw materials and new manufacturing processes that produce lower CO2 emissions. For that Polytan requires experienced partners from the industry, which the Burgheim sports surface specialist has found in the world market leaders Braskem, for bioplastics, and Covestro, for polymer materials.

Poligras Tokyo GT – synthetic hockey turf made of 60 per cent sugar cane

The new Poligras Tokyo GT synthetic hockey turf made its début at FSB 2017. It was developed for the hockey pitches of the 2020 Olympic Games in Tokyo in cooperation with the international hockey federation, the FIH. The synthetic turf’s impressive eco-balance stems from the use of the bio-based I’m greenTM polyethylene plastic from Braskem: obtained from renewable raw materials, this plastic accounts for 60 per cent of the base material for the filaments. The sustainable raw material has the same good properties as the original, crude oil-based polyethylene. Many hockey pitches are already equipped with it, including the Sparkassenpark Mönchengladbach and the Bisham Abbey National Sports Centre in England. Another plus point for players and spectators is that the hockey turf is not only more sustainable that its predecessor models, but also much faster, which means exciting matches are in store!

LigaTurf Cross GT – world’s first CO2-neutral synthetic football turf

In the LigaTurf Cross GT synthetic turf, Polytan has presented the first CO2-neutral synthetic football turf in the world at this year’s FSB. It is a refinement of the successful LigaTurf Cross turf in which smooth and crimped fibres were combined for the first time. Like the Poligras Tokyo GT hockey turf, it is made from the bio-based I’m greenTM polyethylene plastic from Braskem. The already excellent eco-balance is boosted even further by the switchover of production to 100 per cent green electricity and the optimised manufacture of the back coating of the synthetic turf.

Fusion GT – sustainable infill made from 70 per cent natural material

Polytan’s Green Technology product range now contains an infill made from renewable raw materials that significantly improves the playability of the synthetic surface in all weathers and offers first-class functional sports properties. The Fusion GT is a combination of selected, highly elastic EPDM plastics and particularly sustainable raw materials. Its elasticity enhances player comfort and contributes to active player protection against injuries and grazes. Despite its impressive eco-balance, the infill is resistant to UV and weathering and robust against mould formation. The particular shape of the crumb and the low bulk weight reduce the infill quantity required by around 20 per cent – another aspect that improves the sustainability of the product.

PolyBase GT – elastic layer with CO2-reducing binder

Elastic layers form the basis of modern synthetic turf systems from Polytan, which retain their consistently high elasticity for more than 30 years. They are made from recycled elastic materials. The innovative PolyBase GT product has been made even more sustainable by the use of a new binder from Covestro, the manufacture of which uses carbon dioxide as the raw material, saving on fossil resources such as crude oil.

Polytan presented the unfilled LigaTurf Motion synthetic turf at FSB 2019:

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Polytan presented the unfilled LigaTurf Motion synthetic turf at FSB 2019:

Three yarns, no infill

A highly functional synthetic turf system for football that doesn’t use infill crumb? Thanks to Polytan, what was previously only standard in field hockey is now also finding its way into the world of amateur and professional football. LigaTurf Motion, the product innovation presented at this year’s FSB, combines three different synthetic yarns in one system for the first time, offering playing properties that come very close to the sand and rubber-filled synthetic turf systems that have been proving their worth for many years.

Polytan has responded to the public debate about infill in Germany over recent months by developing a synthetic turf for football that doesn’t use a rubber crumb, cork or any other performance infill whatsoever. What is so special about the innovation is that it doesn’t come at the expense of the playing properties of the pitch – they remain roughly as good as those of the sand and rubber-filled synthetic turf systems that have been established for many years, where it is the infill that is primarily responsible for the good playing properties and player protection.

With its LigaTurf Motion, Polytan has now succeeded in bringing onto the market a synthetic turf that is also suitable for football despite the lack of infill. It was the clever combination of three different synthetic yarns in one product that made this development possible.

Three filaments, one synthetic turf system

The first LigaTurf RS+ filament used in the LigaTurf Motion is smooth and was originally developed for synthetic turf systems that are employed in professional football especially. Since the LigaTurf RS+ filaments are longer than the rest of the surface of the turf, they stand out visually and also ensure a pleasantly soft feel on the skin when tackling. Other positive properties of the fibre include a very good rebound capacity and high resistance to wear.

The second filament, the LigaGrass Pro yarn, has a crimped structure, helps to stabilise the turf and generates the necessary traction for the footballers. Fullness and an appearance similar to natural turf are provided by the third filament in the group, the likewise crimped and particularly soft Synergy yarn. All three filament types are hard-wearing and UV-stable, while the patented CoolPlus pigments reduce the amount by which the surface of the turf heats up on hot days.

The TriColour scheme combining three shades of green in one yarn gives the pitch a fresh and natural look. Friedemann Söll, Chief Product Officer Region EMEA of Polytan, sees enormous potential in the product development presented for the first time at FSB: “The LigaTurf Motion CoolPlus allows us to offer all football clubs an easy-to-maintain synthetic turf system with very good playing properties that doesn’t use any infill whatsoever.”

RSI and RHENAC Greentec AG merge sales and operational activities

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Recreational Systems International (NL) and Rhenac Greentec AG (DE) have merged their sales and operational activities for the Rhenac Greentec LED grass care applications for sports. Believing in the state-of-the-art Rhenac Greentec AG technology, RSI has also invested in the German company to support the research activities and to accelerate their introduction of innovations.

RSI and Rhenac Greentec AG will pursue capitalization of its superior knowledge and technology to grow its dominant role in the market for grass care by means of LED technology. The fast growth that both organizations have experienced, the opportunities the markets offer on a global scale and the continuous professionalization of both organizations have led to a more intense cooperation.

The product portfolio includes rigs with LED luminaires that speed up grass seed germination, enable healthy grass growth and support the setting of grass, as well as UV-C technology that prevents fungus, algae and diseases from growing and settling.

Rhenac Greentec is also a big player in the market for LED systems for urban farming and biomass production.

Horst Theisen, CEO of Rhenac Greentec AG, explains: “Rhenac Greentec has been researching the effect light can have on rootzone and leaf development for many years. In 2012 we decided to merge our knowledge of the light spectrum with the latest LED technology. LED has the advantage of being able to produce a much wider light spectrum. Our achievements since in the sports grass, biomass and agricultural industries have resulted in a fast growth for both our business lines.

The strengthening of our ties with RSI and the investment they have made, will guarantee that we can continue developing new products. It will also prepare us for the replacement onslaught we anticipate for conventional grass grow systems. LED technology has proven its quality, reliability and viability. As our LED technology is being used in various professional sports venues around the world already, it is import for us to scale up our organization without jeopardizing the quality and reliability to ensure we are able to answer the demand we anticipate. Hans Borgers, who will become our operations manager, brings 15 years of experience as organizational interim manager to our team. RSI partner Arnoud Fiolet, who will become our commercial director, is a turf professional with 25 years of global business development experience.”

Arnoud Fiolet adds. “We are thrilled that we can continue our journey by assuming operational and sales responsibility for the Rhenac grass growth and grass care business. The synergy between the two companies adds value to our stadium turf concept which encompasses hybrid turf, heating, covering, protection and LED grass grow and grass care maintenance technologies. It is a complete package for professional sports venues that desire a perfect pitch. With over 500 stadiums around the world currently considering replacing their conventional grass grow system by advanced LED technology, our proven and superior LED technology has made us the technological market leader for grass care. We have now positioned ourselves to seize the opportunity.”

Labosport Fiber Performance Index helps French customers chose landscaping turf

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With artificial grass being increasingly used for landscaping applications around the world (gardens & terraces, recreational & parks, urban landscape beautification), Labosport decided to launch in 2017 the Fiber Performance Index for landscaping turf, a declination of its FPI index for sports turf.

The FPI for landscaping turf is an objective laboratory assessment of the artificial turf, with tests designed based on Labosport 25 years quality control experience. Tests focus on characteristics most frequently sought out by end-users and clients, on top of color and aspect: softness, durability and environmental compliance. For instance, the turf is submitted to intense UV radiations followed by mechanical wear with the Lisport™ machine, which allows to simulate several years of ageing in the laboratory.

The index has been adopted by top quality manufacturers, in France and in the US, allowing French clients of the retail gardening chain botanic® to choose the turf quality that corresponds the most to their need.