Circular Rubber Sports Flooring

Circular Rubber Sports Flooring: A strategic roadmap towards a circular business for Stockz

Kappenburg, Abel (TU Delft Industrial Design Engineering)

van den Hende, E.A. (mentor)
Wallner, T.S. (graduation committee)

Delft University of Technology

Strategic Product Design

2022-07-27

Rubber is by the European Union stated a critical material (Critical Raw Materials, 2020). For our society the material is essential but can be depleted. The search for circular solutions for rubber is urgent.

In 2020 27.4 million metric tons of rubber has been produced globally (Tiseo, 2021). Around 70% of all produced rubber is used to create tyres (About rubber, z.d.). creating one of the biggest single product waste streams in the world.

Rubber granulate is a material made by recycling tyres. Stockz is a company which creates rubber sports flooring solutions for fitness gyms and sport clubs from these rubber granules. Delivering a safe space for athletes, reducing sound and protecting the base floor from the impact of falling weights. The life of the rubber material is extended but still after this 2nd life cycle the product ends like waste.

In this project circular strategies are examined to prolong product and material life as long as possible. The 3 most promising circular strategies, Reusing, Remanufacturing and Recycling were chosen to evaluate on feasibility, viability and desirability. Based on tests to create 2nd cycle granules and rubber sports flooring solutions the feasibility is proven for the recycling strategy. Reusing flooring is also possible. Remanufacturing is based on interesting ideas and therefor is plausible but not proven feasible.

Interviews with clients, end-users and production partners gave valuable information on their view on the strategies. An idea generation session to redesign for remanufacturing gave new ideas how to create a more circular product. Life Cycle Analysis were made for the current situation and the 3 strategies. Resulting in a decrease of CO2 with the use of the strategy reusing by 11%, remanufacturing by 15.5% and with recycling by 17%.

Next to this circular business models were examined which led to 2 different retrieval services for indirect sales clients and a rent/hire business with direct sales clients. Cost calculations were made and discussed with clients and end-users. The viability of the reuse strategy is proven. The viability of the remanufacture strategy is because of the new idea not certain but plausible after some investments. The viability of the recycle strategy was not proven because of a higher price than the current product which was not desirable. A 2nd cycle recycled flooring solution could be viable for other clients or end-users than interviewed who are willing to pay more for a more sustainable product.

From these results a strategic roadmap was made towards the vision of Stockz having a circular business. A MVP to start the retrieval service in 2023 is the first horizon going towards the second horizon in 2024 were pre-loved (used) products and 2nd cycle products are being sold.

Circular Design Strategies
Roadmap
Life cycle assessment (LCA)

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Student theses

master thesis

© 2022 Abel Kappenburg