Granulogy:

Success based
on knowledge
of rubber.
EPDM granules of
the highest quality
for sports and
recreational surfaces.
Introduction
Some time ago, we were presented with the continuous production process was developed. This
challenge of making our knowledge about rubber patented technology is now in its third generation
mixtures easier to understand for non-professionals and remains equalled within our sector.
who want to learn more about how EPDM and other
elastomers are developed and produced and what Our highly motivated team has brought Gezolan AG
their special characteristics are. to the very pinnacle of our sector. Technological
leadership, innovations and added value are concepts
This task has proven to be very difficult. As various that are deeply rooted in the company culture of
experts of Gezolan and scientists from our sister Gezolan.
companies in the Kraiburg Group became involved,
the challenge appeared to be come even greater. I would like to thank the generation that made the
realisation of this dream a possibility, as well as my
The project lasted significantly longer than expected. current colleagues, whose commitment and desire
Combining know-how gathered over more than for success are second to none.
40 years and then concentrating it into a few pages
for an audience of interested parties is a very stimu- I am proud to be able to offer you this compendium
lating, yet difficult task. of information and I hope it will contribute to your
success. I hope that you find the reading to be inte-
Thanks to the engineering skills and intuition of resting and enjoyable.
my predecessor, and thanks to the know-how and
support of Kraiburg Holding, a new, ground-breaking Josep Roger, CEO
Native Amazonians during
the rubber harvest at
a caoutchouc plantation.
The history of caoutchouc
It took hundreds of years for caoutchouc It was not until nearly three hundred years later,
and its synthetic successors to conquer the in 1736, that Frenchman Charles Le Condamine
world. Known in Europe since the time of sent a package with caoutchouc to Paris from the
Columbus and the discovery of the Americas, Amazon. Le Condamine was on an expedition and
it took two drastic events to pave the path provided the first detailed report on the use of
for rubber. Goodyear is the name of an the material by the indigenous people. One of his
important pioneer and is still a well-known fellow countrymen, François Fresneau, spend the
product. following years on location researching and doc-
umenting caoutchouc and sent numerous reports
The history of modern polymers began long ago back to Europe. He discovered that latex milk is
and it took many years of research and develop- soluble in turpentine, which first made transport
ment to arrive at the current state of technology. over great distances possible. From that point on,
a new age in caoutchouc production began.
The first reports of the indigenous peoples of the
Amazon and their use of rubber first appear in the A pioneering and still important event in the
history books at the time of Christopher Columbus history of caoutchouc processing is the invention
and the conquest of the Americas. It is known, of vulcanisation by Charles Goodyear in 1839.
among other things, that the natives played with This process makes it possible to convert plastic
a rubber-like ball made from dried milk from caoutchouc, which has very low heat and ageing
a tree. resistance, into elastic rubber.

Charles Goodyear,
founder of
vulcanisation
in 1839
One of the main milestones in the modern chem- latex with some chemical products established a new
istry of polymers was achieved during the World War direction in research. The aim is to create long mole-
II. There was an extremely high demand for rubber cular chains by beginning with specifically chosen
products at the time, which caused a considerable monomers. This makes it possible to cross the elastic
shortage in their availability. As a result, there was properties of natural caoutchouc with alternative
a strong motivation among the various international raw materials. The result is the discovery of modern
forces to conduct uninterrupted research. The earlier polymers, which initially included elastomers and
discovery that the characteristics of caoutchouc – thermoplastics, with the later addition of thermo-
or natural rubber – can be modified by cross-linking plastic elastomers.

The milk (latex) of the

caoutchouc tree is the
basis for production of
natural caoutchouc.
The basic raw material
Synthetic caoutchouc, the synthetic alternative Normally, elastomers are thermally stable polymers.
to natural caoutchouc, excels over its natural The long polymer chains are linked during the hard-
forefather with its specific characteristics. ening process. The molecular structure of elastomers
The base product of these new elastomers is can be described as a structure of ‘spaghetti with
special fractions of crude oil. The material is meatballs’, wherein the meatballs represent the links.
distinguished by high elasticity, flexibility and The elasticity is based on the agility of the chains
resistance to heat, ozone and oxidation. There to change in position and distribute tension. The
are basically two different elastomers that are covalent bond ensures that the elastomer returns to
important for modern production of granules. its original position as soon as tension is no longer
They differ primarily in their behaviour when applied. Elastomers are extremely flexible and can
heated. be stretched by 5 % to 700 %, depending on the
specific type of material.

Special fractions of
crude oil are the base
product for elastomers
The molecular structure of elastomers can be de- Thermally stable elastomers, such as EPDM have
scribed as a structure of ‘spaghetti with meatballs’, outstanding resilience and are highly resistant to
wherein the meatballs represent the links. atmospheric influences.

With its specific

properties synthetic
caoutchouc is superior
to natural caoutchouc.
The elastomers can be classified as follows according electrical insulation, such as very good resistance to
to their behaviour at high temperatures: atmospheric influences, media containing acids and
Thermoplastic elastomers These elastomers alkali and especially chemical products. However, it is
become soft and formable as the temperature in- susceptible to attacks from oils and petroleum.
creases, although their properties do not change if
they have been melted and formed repeatedly. This Caoutchouc mixtures such as those based on EPDM
category includes styrol thermoplastics such as SBS are produced from formulations that include a multi-
and SEBS, olefins (TPO), vulcanised thermoplastics tude of organic and inorganic components. Between
(TPV) and thermoplastic polyurethane (TPU). 20 and 30 components can be used in a formulation.
The diversity with which its properties can be changed
Thermally stable elastomers These elastomers through various combinations is one of the most
do not change in form and retain their strength. noteworthy features of rubber technology. In general,
The majority of elastomers, including EPDM, are a typical formation consists of an elastomer base,
part of this group. reinforcing agent, additives to promote the process,
EPDM (ethylene, propylene, diene, monomer counteract decomposition and promote the vulcani-
(M-class)) is an elastomer with excellent resistance to sation system.
abrasion and wear. It also has very good properties as
Vulcanisation and cross-linking
The vulcanisation stage is required to change cross-linking or linkage. The tensile force, hardness
the plastic caoutchouc to an elastic and thermo- and resistance to wear are increased with vulcanis-
plastic state. The loose, disorderly molecular ation and the elongation, permanent compression
chains are cross-linked during the process with and solubility are reduced as a result. Resistance to
sulphur or peroxide. These links ensure that tension and elongation at break show are optimised
the molecular chains return to their original thanks to the changes that arise due to the degree of
position after force is applied. cross-linking.

The vulcanising agents are used to delay or accel- A vulcanisation system with sulphur is the most
erate the cross-linking system. These are chemical frequently used vulcanising agent for the production
substances that form a three-dimensional network of rubber. Sulphur is insoluble in rubber, which makes
and establish links between the segments of the it migrated to the surface before the vulcanisation.
chain due to reaction with the rubber molecules. It is inexpensive, has very low toxicity and is also
This process is known as vulcanisation, hardening, compatible with other additives.

Loose molecular chains that are disorderly intertwined. Molecular chains linked with sulphur.

After tensile force is applied, the molecular chains The three-dimensional cross-linking keeps the mole-
remain offset and the thermoplastic does not return cular chains together; after force is applied, the
to its former position. elastomer draws back together to its original form.
A vulcanisation system with peroxide is the be taken during the handling and storage, because
most common system among sulphur-free systems. it involves substances with risks that can generate
It is generally used for rubbers with an elastomer an unpleasant odour. It also involves substances that
base that does not contain any double linkages in its react with other components, which is why the use of
molecular structure and thus cannot be vulcanised antioxidants is limited.
with sulphur, because an alternative vulcanisation
process that is capable of reacting with only one The vulcanisation must take place without oxygen,
linkage is required. Although the formulations based because with the presence of oxygen the transfer
on vulcanisation with peroxide have good thermal radical of the rubber chain oxides and the degrada-
ageing and flexibility properties, precautions must tion process begins.

Sulphur is the most widely

used cross-linking agent
for vulcanisation.
The process
In formulations with partially up to thirty dif- mixers after a precisely defined mixing procedure.
ferent components, the focus is on the correct TPE / TPV are normally mixed continuously in extrud-
mixture and distribution of ingredients. ers and auger mixers. This process is also applied for
the production of compounds in the rubber industry
The mixture of individual components and simul- in isolated cases. Continuous mixing in extruders for
taneous distribution – dispersion – in the polymer the production, such as the process used at Gezolan,
matrix is a significant stage in the production of is advantageous, because the granules can be pro-
rubber and the manufacture of TPE / TPV mixtures. duced immediately after exiting the extruder.

In the rubber industry the mixture, the compound, is The cross-linking – vulcanisation – takes place
usually produced discontinuously in so-called internal in a second stage or, in continuous production,

A perfect
compound.
immediately after exiting the extruder. The vul- in the granulating plant. The fine dust arising in the
canisation processing time is controlled and the process and / or the rubber dust can be added to the
process temperature is regulated to 150 to 220 °C. respective base compound for the next production
The cross-linking of TPV usually takes place in situ – without a reduction in quality.
i.e. during the mixing process or with addition of
pre-cross-linked polymers.

Depending on the technology that is used, the

granulation takes place in an additional step or
the granules after extrusion and subsequently Mischen der Vulkanisation Granulierung
Mixture of Vulcanisation Granulation
vulcanised are produced in the desired grain size einzelnen
individual bei 150 bis 220 °C
at 150 to 220 °C ininthe
gewünschte
desired
components
Bestandteile grain size
Korngrösse

Granulation to the
desired grain size.
Which elastic granules are used for
today’s sports facilities?
The use of ground coverings for sport is divided this document, because they have a pre-existing
into four major categories: Granules made formulation and have not been created specifically
of recycled tyres (wrongly referred to as SBR to fulfil the required function of a synthetic ground
granules), granules made from recycled rubber, covering for sporting activities, although these prod-
EPDM granules and TPE / TPV granules. ucts are commonly used for this type of application
with the benefits and risks that their use entails.
The granules that originate from recycled tyres
or other types of rubbers are not addressed in

EPDM TPE / TPV

Resistance to mineral oil

Elasticity

Ozone resistance

UV resistance

Mechanical strength

Compression

Acid resistance

Hydrolysis resistant

Quality CONSTANT CONSTANT

Heat resistance + °C 130 °C

Cold resistance – °C 50 °C

Pollutant content DEEP DEEP

Colours ARBITRARY ARBITRARY

excellent satisfactory poor

Are conventional thermoplastic granules
suitable for use in synthetic surfaces and
artificial turf?
Rubber, such as EPDM granules, and TPE or TPV Thermoplastic elastomers, TPE or TPV, are only
granules can be tailored by the manufacturer, permanently elastic within a limited temperature
i.e. adapted, formulated and produced to suit range – although it is wider than that of TP. The
the respective application. elasticity is usually lower due to the lower number
of chemical cross-linking points with TPV, or the
The elastic behaviour of polymers depends heavily purely physical cross-linking with TPE.
on the molecular structure. The macromolecules of
thermoplastics, thermoplastic elastomers and – with Elastic polymers, such as caoutchouc, are usually
the exception of natural caoutchouc – all types of characterised by claw-like, crystalline or amorphously
caoutchouc, including EPDM, are manufactured structured molecular chains. With a cross-linking
synthetically. The original product is special fractions of macromolecules that can be carried out with
of crude oil (mineral oil). With the polymerisation of caoutchouc, the shift and flow under the influence
monomers, the molecular structure and distribution of heat.
of components is determined with copolymers or
terpolymers. The chemical, wide-meshed cross-linking of
caoutchouc with sulphur or peroxide, usually at
Thermoplastics, TP, usually having long-chained, temperatures of at least 150 °C, the vulcanisation,
linear and non-cross-linked macromolecules, gener- produces a thermally stable product that is also
ally have a low elasticity within a limited temperature permanently elastic – rubber or elastomer. The
range in comparison with elastomers and TPE / TPV. sporting and protective properties are maintained
They are thermally formable and soften at higher to the greatest possible extent in the temperature
temperatures, which means they are not suitable range to be expected.
for use in synthetic surfaces and artificial turf.

Vulcanising agents
are used to enable the
cross-linking system
The high-performance EPDM
surface complies with
all existing national and
international standards.
EPDM rubber granules
EPDM is the predestined elastomer for all Forty years of know-how for the GEZOFLEX product
outdoor applications and is the first choice group (main application for athletics, multi-purpose
for use in sports facilities. fields and children’s fall protection) and extensive
experience for GEZOFILL (scatter granules for artificial
The saturated ethylene-propylene polymethylene turf) have enabled the high quality level of GEZOLAN
main chain of the polymer (no double bond suscep- EPDM rubber granules. Experience, continuous
tible to ozone and oxygen) assures very good resist- adjustment to increasing demands (KVP), select raw
ance to weathering and ageing. Even unprotected, materials, the modern, computer-controlled contin-
this is better than typical tyre rubber mixtures having uous production and consistent process and quality
elastomers with reactive double bonds in the main monitoring (ISO 9001 since 2003) guarantee the
chain and which, without appropriate stabilisation quality of GEZOLAN EPDM rubber granules that our
with antioxidants and antiozonants, can only with- customers value.
stand use outdoors at higher temperatures for
a short time without a loss of function. The granules of both product groups can be dyed
according to customer wishes. There are currently
The thermally stable properties are only achieved 21 different colours available to choose from. The
by means of cross-linking with sulphur or peroxide. colour consistency after UV weathering is tested
As is the case with all elastomers, the correct selec- and monitored outdoors and in our laboratory
tion and quantity of fillers, softeners, UV stabilisers, (with xenon and QUV testing).
cross-linking system and polymers will significantly
change and optimise the properties. For instance, Colour granules heat up significantly less in solar
EPDM polymerisation can vary according to ethylene radiation than black recycled tyre rubber granules.
or propylene content, the type and quantity of diene The existing national and international regulations
and in molecular structure and thus have different and standards are fulfilled without limitation by
basic properties. the GEZOFLEX products for synthetic surfaces and
GEZOFILL for artificial turf.
Our EPDM rubber granules are cross-linked with With the use of microporous GEZOLAN EPDM
sulphur like the elastomers in tyres. The cross-linking granules, the functional properties for sport and
system for GEZOLAN EPDM granules is precisely protection can be further optimised. The reduced
attuned to existing environmental requirements. For density or volume increase achieved in the process
instance, the zinc content was reduced to level that means less material is needed by the user and thus
is unusually low for the rubber industry. The softener a lower price.
used by GEZOLAN is aroma-free and, in contrast
to the aromatic or naphtenic softeners used in tyre Requirements on flame resistance in accordance
mixtures, have the lowest PAK content, at a level that with EN13501-1 are met without the use of toxic,
is irrelevant for the environment. A strict conside- environmentally harmful halogen or phosphorous
ration of environmental requirements also applies compounds.
for the other ingredients.
EPDM granules demonstrate good resistance to
Granule manufacturers carried out cross-linking of water, antifreeze and diluted acids. However, like
EPDM granules with peroxide instead of sulphur. other granules, they are not resistant to mineral oils
The purpose was to facilitate compliance with envi- and fuels.
ronmental requirements. Unfortunately, presumably
due to incomplete cross-linking, adhesion and clump- The adhesion, cohesive bonding, of GEZOFLEX
ing of the artificial turf filler granules occurred after granules with polyurethane bonding agents has been
only a short period of use, which is the equivalent demonstrated to be very good for GEZOLAN granules
of a total loss of function. This resulted in a general due to the formulation of the recipe specifically for
uncertainty of the use of EPDM granules in the this purpose. It is better than the PUR adhesion of
market. tyre granules, which is reduced due to the migration
of microcrystalline growth on the granule surface.
With a correctly adjusted cross-linking system
and sufficient cross-linking conditions (time and EPDM granules are thermally recyclable in bonded
temperature), however, our experience has shown and non-bonded form, which means the energy used
that sulphur cross-linked and peroxide cross-linked for the production can be recycled through combus-
EPDM rubber granules are suitable for practical use tion in incinerators or in the furnaces of the cement
in compliance with environmental requirements. industry.
TPE / TPV granules
TPE / TPV granules are mainly used as filler for artifi- At lower temperatures the reversible hardening
cial turf. Due to the difference in quality of various is greater than that of recycled tyre and EPDM
TPE / TPV materials, a differentiation between suita- granules.
ble and unsuitable materials must be made for filler
granules. Like EPDM granules, the correct formu- Like all thermoplastics, TPE / TPV are basically
lation is crucial for long-term suitability in artificial recyclable, with an expected period of use of more
turf – in other words, the choice of polymers, filler than 10 years. However, a loss in value must be taken
material, softeners, UV stabilisers and cross-linking into account due to degradation of the polymers.
agents (only for TPV granules). With the use of granules in artificial turf, mixture
with sand or protective ingredients is possible,
The suitable TPE / TPV granules can have similar which complicates an original recyclability.
basic properties as EPDM granules. Nevertheless,
due to the lower cross-linking of polymer chains, A pattern of characteristics comparable to EPDM
limited performance at higher environmental granules necessitates a higher price.
temperatures must be taken into consideration.

Also suitable for elastic

surfaces: infill granules
from Gezolan AG.
Experience, technology and additional expertise
Since 1968 GEZOLAN has gathered extensive we made an enormous advancement with the
experience in the production of EPDM granules conceptual design of a new production model that
for use in sports and recreational applications. would result in the production of an incomparable
The company also benefits from synergies with end product. Today we still enjoy a privileged
other companies in the KRAIBURG group, which market position and a level of quality that remains
enables access to technologies associated with unequalled by any of our competitors.
rubber compounds, thermoplastics and recy-
cling and production techniques. As the 1990s progressed, new market tendencies
opened a new segment. The new generation of arti-
Towards the end of the 1980s, we began to question ficial turf systems for football required a filler granule
the technology used for the production of rubber that must provide the necessary elastic factor. There
compounds. Over the course of innovative devel- currently a wide variety of options for attempting
opment, and with a sizeable economic investment, to achieve this function. Based on EPDM granules,

Artistic ambience
in St. Gallen: the red
square made of
EPDM granules.
thermoplastics, organic or hybrid filler materials and always on the basis of an EPDM compound. Over
recycled products, there is a broad spectrum of solu- the course of time and after evaluation of various
tions available to the customer. options and on the basis of experience that we have
gathered, we are absolutely convinced that the
Since this is a market niche, product requirements EPDM-based components will continue to be the
expand on a day-to-day basis. The rules and require- most reliable option for this application and for
ments stipulated by authorities, concerns relating to fulfilment of the expected function.
the biomechanical aspect, environmental regulations
and aspects of recycling all represent very important We were able to formulate a product that provides
challenges for the sector in consideration of changing a reasonable response with respect to the playing
conditions. characteristics, environmental limitations and ageing
In 2001 GEZOLAN launched for first generation of properties and simultaneously offers additional
the filler material GEZOFILL. It is specially formulated characteristics that no other product on the market
for this application and has been regularly updated, has been able to match.
Glossary

Elastomers are solid, yet elastic formable plastics. Latex Is a material from different types of plants that
The plastics can be formed elastically with tension is used to produce natural caoutchouc. This term also
and pressure, but then return to their original shape. refers to rubber products that are produced from
caoutchouc.
Thermoplastic elastomers (TPE) are plastics that
behave similarly to traditional elastomers at room Molecule The smallest unit of a chemical compound
temperature, but can deform plastically with the of two or more atoms that cannot be divided further
addition of heat. without changing its properties.

EPDM (ethylene propylene diene monomer Monomer Individual module of polymers. Each mol-
(M-class) rubber) is an elastomer that is highly ecule exists on its own.
resistant to weather influences such as UV, ozone,
strong acids and bases and high and low tempera- Polymer Basis of every plastic. Macromolecules that
tures. However, this elastomer has very poor are formed from numerous equal or similar modules
resistance to mineral oil and grease. (monomers).

Rubber Name for vulcanised, elastic caoutchouc. Polymer chain Polymers linked in the shape of
a chain.
Caoutchouc Collective term for elastic polymers
from which rubber is produced. Natural and synthetic Vulcanisation Refinement of caoutchouc in which
caoutchouc are differentiated between. Natural the addition of sulphur or peroxide provides the
caoutchouc is primarily composed of latex from the plastic caoutchouc with elastic properties.
caoutchouc tree (hevea brasiliensis).
EPDM colour spectrum of Gezolan AG.

060 084 076

WEISS LEUCHTBLAU BEIGEBRAUN
WHITE BRIGHT BLUE BEIGE BROWN
BLANC BLEU ILLUMINANT MARRON MOYEN
BLANCO AZUL BRILLANTE MARRÓN CLARO
RAL 9010 RAL 5012 RAL 8024

056 064 046

EGGSHELL BLAU BRAUN
EGGSHELL BLUE BROWN
COQUILLE D’OEUF BLEU MARRON
CÀSCARA DE HUEVO AZUL MARRÓN
RAL 1015 RAL 5015 RAL 8025

066 054 065

BEIGE DUNKELBLAU GRAU
BEIGE DARK BLUE GREY
BEIGE BLEU FONCÉ GRIS
BEIGE AZUL OSCURO GRIS
RAL 1014 RAL 5010 RAL 7038

069 052 055

GELB PINK MITTELGRAU
YELLOW PINK MIDDLE GREY
JAUNE ROSE GRIS MOYEN
AMARILLO ROSA GRIS MEDIANO
RAL 1002 RAL 4003 RAL 7037

089 044 045

LEUCHTGELB LILA DUNKELGRAU
BRIGHT YELLOW LILAC DARK GREY
JAUNE ILLUMINANT LILAS GRIS FONCÉ
AMARILLO BRILLANTE LILA GRIS OSCURO
RAL 1012 RAL 4005 RAL 7011

087 083 021

LEUCHTGRÜN LEUCHTORANGE SCHWARZ
BRIGHT GREEN BRIGHT ORANGE BLACK
VERT ILLUMINANT ORANGE ILLUMINANT NOIR
VERDE BRILLANTE NARANJA BRILLANTE NEGRO
RAL 6017 RAL 2008 RAL 9004

Die abgebildeten Muster sind gedruckt und

067 082 nicht 100 % farbverbindlich. Bitte verlangen
GRÜN LEUCHTROT Sie die Original-Farbmuster.
GREEN BRIGHT RED
VERT ROUGE ILLUMINANT The shown colours are printed and could
VERDE ROJO BRILLANTE therefore not match 100 % the real colour.
RAL 6021 RAL 3017 Please ask for actual samples.

Les couleurs sont imprimées et de ce fait ne

047 062 correspondent pas à 100 % à la vraie couleur.
DUNKELGRÜN ROT Merci de demander des échantillons.
DARK GREEN RED
VERT FONCÉ ROUGE Los colores aquí mostrados están impresos
VERDE OSCURO ROJO y podrían no ajustarse al 100 % al color real.
RAL 6005 RAL 3016 Sírvase solicitar muestras físicas.
GEZOLAN AG // Werkstrasse 30 // CH-6252 Dagmersellen // Switzerland TRUE ISO TOXIC
T +41 62 748 30 40 // F +41 62 748 30 41 // www.gezolan.com SWISS
PRODUCT
9001
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