With the commissioning of the fully automated PM3D® machines in 2022, we laid the first foundation for the climate-friendly full automation of the entire Gum-tech® production line. After initial challenges—particularly with filling mechanisms and several technical adjustments—the system ultimately met expectations in 2023. High inventory levels enabled fast delivery to both existing and new customers. At the same time, the precision of the new machines reduced production waste by 70%, allowing us to maintain stable pricing throughout the year. Automation also delivered significant energy benefits, lowering total energy consumption by approximately 30%.
Early Analyses
The new standards achieved through automation brought new requirements. Because the production process is now highly consistent and human error has been minimized, it made sense to test—and where appropriate certify—the new quality level. In 2023, the Puzzle Mat 3D® underwent testing for impact reduction (joint protection), ball response, permeability, and certified HIC fall heights. These results make it possible to clearly define the system’s performance characteristics and establish stable reference values for the consistently produced tiles in the coming years.
New Testing Procedures
Rubber tile production depends on the reuse of high-quality rubber granulate. To better control granulate production, we prepared in 2023 to install new Gum-tech® recycling systems directly adjacent to the automated production line. The goal: streamline the material flow, ensure 100% control over the recycling process, and secure greater quantities of granulate for future product development. With these new systems, Gum-tech® will also introduce a complete recycling service—allowing customers to return old rubber surfaces for reprocessing through a recycling fee.
