Artificial Turf Recycling for On-Site Infill Separation
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Solution Overview
Problem
Existing artificial turf recycling systems are inefficient, costly, and overly complicated, failing to effectively separate and reclaim materials for reuse due to slow processing, high equipment complexity, and over-processing, which results in materials that are not economically viable for re-use.
Innovation Solution
A mobile and non-mobile artificial turf recycling system that includes shredding, screening, and heating equipment to efficiently separate infill materials such as sand and crumb rubber from the backing and fiber layer, allowing for on-site or near-site processing, reducing the need for transportation and equipment, and utilizing heat to facilitate separation and reuse of materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing artificial turf recycling systems are used, then materials can be separated and reclaimed, but the processing speed is slow and the system is overly complicated
Solution Approach 1:
The recycling system is divided into distinct functional modules: a cutting module that cuts turf into strips, a shredding module that processes strips into particles, and a separation module that separates infill from backing. This segmentation allows each module to be optimized independently for speed and simplicity, resolving the contradiction between processing speed and system complexity.
Solution Approach 2:
The patent combines multiple processing functions (cutting, shredding, separating) into an integrated mobile recycling system that can operate on-site. By merging these functions into a single coordinated system rather than separate centralized facilities, the patent achieves faster processing while managing complexity through functional integration.
2Loss of time
If centralized recycling facilities are used, then material separation can be performed, but transportation costs and time increase significantly
Solution Approach 1:
The recycling system is deployed to the construction site before new turf installation begins. By performing the recycling action on-site at the preliminary stage, the system eliminates the need to transport heavy infill materials to centralized facilities, significantly reducing transportation time and costs while the system remains mobile enough for easy deployment.
3Manufacturing precision
If existing recycling systems process materials to high purity standards, then material quality improves, but processing costs and time increase
Solution Approach 1:
The separation module uses a combination of screening mechanisms and air classification that provide sufficient separation quality for construction reuse without requiring excessive purification. This local quality approach matches the separation capability to the actual reuse requirements, maintaining productivity while achieving adequate material quality for its intended purpose.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly reduces processing time and costs by enabling efficient separation and reuse of infill materials directly at the site of artificial turf replacement, avoiding the inefficiencies and high costs associated with transporting materials to centralized facilities, and allowing for the recycling of materials into valuable secondary products like cement kiln fuel.
Implementation Method 1
heating equipment to efficiently separate infill materials such as sand and crumb rubber from the backing and fiber layer
Data Source
AI summary
An artificial turf recycling system and method includes multi-phase processing of shredded turf laden with infill from an 8 inch minus product size down to about 1 mm minus particle size or less with a combination of special purpose equipment. Clean processed sand and crumb rubber may efficiently and expeditiously be reused in the installation of replacement artificial turf. Mobile apparatus and equipment may optionally be utilized proximate the site of the artificial turf needing replacement.