Green Foam Blanks

Enviromental Media Association Newsletter April 2011

2011-04-22T18:24:00.001-07:00

ReSurf Recyling

Joey Santley, a surf industry veteran, believes that surfers are by nature environmentalists even though the surfing industry leaves a tremendous amount of toxic waste on a daily basis. In 2006, Joey founded REsurf.org, a non-profit dedicated to creating the best practices and awareness for dealing with the internal waste the surfing industry creates thereby extending the life of the material as far as possible. The foundation also focuses on educating children how to live more environmentally responsible lives.

Joey is determined to be a green leader in the $7 billion dollar surf industry and leave the world a better place for future generations. Hoping to help reduce landfill waste, Joey and his business partner Steve Cox founded the company Green Foam Blanks. Green Foam Blanks makes environmentally responsible surfboard blanks, forging new boards from the polyurethane waste of freshly made surfboards. "During our exploration and R&D efforts, Steve and I figured that the next logical step was to create a cradle to cradle recycling system for surfboard foam, since it makes up the majority of the waste pile we create," said Joey. Their innovation recently earned Green Foam the Environmental Product of The Year award from the Surf Industry Manufacturers Association (SIMA).

And if that’s not enough, Joey recently created a pollution fighting superhero character, Kid Natural, who was born on Earth Day to Mother Earth and King Neptune. Because his parents were sick with pollution, Kid Natural was born with autism. Joey plans to market products, books, and cartoons with this character to raise awareness and understanding of the handicap. Says Joey, "My brother and my son have autism, so this is an issue close to my heart." Joey believes that if he can contribute to creating a better-greener-product while helping to raise consciousness about autism, he will reach true success. "I have learned more on this journey than any other in life and have found great joy and peace knowing that I am working on solutions rather than being part of the problem." www.greenfoamblanks.com

Earth Day Free For All: Eco Innovations For A New Era | TransWorld Business

2011-04-22T08:22:00.000-07:00

Earth Day Free For All: Eco Innovations For A New Era TransWorld Business

Green Foam Surfboard Blanks

2011-04-21T07:54:00.000-07:00

Manufacturing Stoke

2011-04-20T11:48:00.001-07:00

http://vimeo.com/21108946

Nike 6.0 and HB Surf Team shape Green Foam "watch video"

2011-03-22T09:09:00.000-07:00

Shaping Green Foam @ The 6.0 Motel No Tell

http://vimeo.com/14067496

The Nike 6.0 Motel No Tell challenged the Huntington Beach High surf team to shape their own board from a Green Foam blank. The crew also got a tour or the Motel, enjoyed some BBQ and designed a tee in the Primo's Customization house. Thanks to Green...

Video from Sima Image Awards 2011

2011-03-22T08:25:00.001-07:00

http://www.sima.com/image-awards.aspx

Surf Biz: SIMA announces Image Award winners

2011-02-08T09:57:00.000-08:00

Surf Biz: SIMA announces Image Award winners

GREEN FOAM INTERVIEW

2011-02-05T10:20:00.000-08:00

Green Foam Surfboard Blanks

2011-02-05T10:18:00.000-08:00

8th Annual SIMA Image Awards Winners & Photos

2011-02-04T14:45:00.000-08:00

8th Annual SIMA Image Awards Winners & Photos

Green Foam wins the SIMA enviromental product of the year

2011-02-04T09:24:00.000-08:00

http://www.shop-eat-surf.com/news-item/2399/sima-image-award-winners/-

Facebook (104)

2010-12-03T07:41:00.000-08:00

Green Foam Is excited to be nominated in the enviromental product of the year category of the SIMA Image Awards-

Environmental Product of the YearCriteria: Awarded to the most exciting, appealing and/or innovative environmental surf product from Spring or Fall 2010 product lines (at retail between January 1 and September 1, 2010).... C...onsider apparel, footwear, accessory, wetsuit, surfboard or any other surf-related
See More
SHOP-EAT-SURF.COM Action Sports Industry News
http://www.shop-eat-surf.com/news-item/2237/sima-image-awards

The MOTORBOAT::

2010-12-02T13:13:00.000-08:00

MODEL DESCRIPTION

Rob Machado wanted to bridge the gap between his Biscuit and Gravy, the Motorboat does that. Low entry rocker along with single to double concave with vee make this board really motor. Super fast and fun in flat faced waves, the Motorboat blends performance and volume into the ideal small to medium wave performance board.

Motorboats are built with either "Greenfoam" or recycled EPS, UV cure resins, and recycled fins, as Rob also wanted to make the Motorboat less impactful on the environment. A limited edition run of 75 boards signed by Rob are planned to have foam waste combined with concrete for water fountains commissioned by Rob's foundation for schools. Size: Knee to slightly overhead; Skill: Novice to advanced

http://www.cisurfboards.com/sb_Motor-Boat.asp

Surfer Magazine - The Interview Issue September 2010

2010-11-06T09:33:00.000-07:00

White Gold: Joey Santley and how surfboard foam dust can save the Gulf. Surfer Magazine - Issue:September 2010

New Future Interview: Joey Santley, Green Foam

2010-10-29T13:47:00.000-07:00

http://vimeo.com/14630960

Into the Blue - Features - Coast Magazine

2010-10-28T11:54:00.000-07:00

Into the Blue - Features - Coast Magazine

Blanks Ready to be cut into Rob Machados new enviro friendly signature board the Motorboat

2010-10-27T14:31:00.000-07:00

A more environmentally friendly Rob Machado board called Motorboat, made with a Green Foam blank, UV cure and resin and a recycled fin, on Nov. 15.

2010-10-20T18:51:00.000-07:00

A visit to CI HQ and business update

By TIFFANY MONTGOMERY | October 20, 2010 06:00 AM

Scott Anderson, General Manager of Channel Islands Surfboards.

While I was in the Santa Barbara area last week, I stopped in at surfboard maker Channel Islands’ Carpinteria headquarters and had an informative talk with General Manager Scott Anderson.

Scott, who started working for the company nearly 20 years ago packing boxes, showed me around the state-of-the-art facility, which Channel Islands moved into about three years ago, and he gave me an update on Channel Island’s business.

According to the ActionWatch Retail Panel, Channel Islands has the highest market share and highest distribution penetration in the shortboards category.

Big upgrade

The Channel Islands headquarters are located in an office park in Carpinteria where on a clear day you can see the ocean and the actual Channel Islands off in the distance.

From the outside, the building looks like any other offices. But inside, there is a sophisticated board making operation, thousands of boards in various states of production and a very cool, loft like aesthetic in the area where offices are housed.

(Channel Islands' loft like offices.)

Scott told me this new space is heavenly compared to the company’s old facility, where the roof leaked and there was no storage.

The credit for the new building goes to Burton, he said, who invested in building a new facility for Channel Islands after acquiring the company in 2006.

“The impressive thing is with Jake (Burton) is that he had enough confidence in us as a group to invest this much in board building in California, and in Santa Barbara – not the cheapest place in the world to do business,” Scott said.

( Blanks that will be turned into boards.)

Jake and former Burton CEO Laurent Potdevin understood that Santa Barbara was the company’s roots, Scott said. The nice thing about the acquisition is that the two companies have very similar cultures and can relate to one another.

“It’s hardgoods to hardgoods,” Scott said. “We have a very like-minded philosophy. Whenever we work with Burton, they get it. They get the hardgoods thing.”

Making boards

(Patrick White laminating a board.)

Over time, Channel Islands has brought more and more board making processes in house and refined them, Scott said.

The company uses blanks from Surfblanks America, US Blanks and South Coast Foam & Fibreglass in Australia. Beyond that, the entire board is made in-house. I saw notebooks in the milling area that had pages and pages of entries listing extensive measurements for every board as part of the quality checking process.

Fifty people work at the company in two shifts. Boards are made from 4:30 a.m. until 11 p.m.

All processes meet strict state and federal environmental guidelines, also not a cheap proposition.

( Finished board inventory.)

The amazing thing to me was to see the inventory of completed boards. The hang in tiers, and the rows go on and on – a maze of boards.

The Carpinteria facility services most of the world – the U.S., Canada, Hawaii, Japan, much of Latin America and about 75% of Europe. Channel Islands also has a production facility in Europe that makes custom boards and boards for the team.

Licensees make boards in Brazil and Australia.

The company does not keep a lot of extra stock, however, because boards have about a three-month shelf life before they turn yellow.

The Carpinteria building can hold 3,000 boards, though it has never been that full, Scott said.

The idea is to “build it and turn it – and be smart about what we build,” he said.

Currently, the company is taking preorders for spring and summer and will begin making the boards about two months before delivery. It also makes a lot of custom boards.

(Kelly Slater's Black Flag model.)

I know some surfboard makers make product overseas. Given the low margins on boards, I asked if that is something Channel Islands would do.

Scott said the overseas model doesn’t work for the company because Channel Islands likes to have control over design, and quality and to get to market fast.

He gave the example of Kelly Slater, who lives nearby in Montecito, coming in one night to work on one of his models.

Kelly sat by the designer as they designed the board on the computer, and by the next day, Channel Islands had a model ready for him to test.

Once it got Kelly’s approval, the company can turn around and get it into the market in a matter of weeks.

“We could get more margin in Asia, but we think the best builders are here, and our quality control process is so extensive – we have complete control,” he said.

Business up

Despite the hardgoods market being tough overall, Scott said Channel Islands business has been up every year, and this year, the company is beating its sales goals.

(Channel Islands Sales Manager Mike Cobb and Product Manager Scott Martinson.)

Scott attributes the strength to Channel Islands strong products, but also to a new focus on forming stronger relationships with retailers.

Historically, Channel Islands just kept its head down and focused on making better surfboards, figuring the rest would take care of itself, Scott said.

While it is still very focused on making the best boards, being acquired by Burton allowed the company to invest in some new positions and infrastructure.

“Before, the product guy was also the guy tarring the roof when it rained, and the guy running the truck and running sales,” Scott said. “Everyone did everything.”

(Big tubes carry dust and particles outside from the milling areas and shaping bays.)

For the first time, the company has a dedicated sales manager, a production manager, a head of marketing. Everyone can focus on his or her job instead of running out to plug a leak in the roof.

“The end result is better product and relationships with retailers – we’re not just answering the phone and reacting,” Scott said.

Now, Channel Islands can spend more time in stores working to make sure key retailers have the right type of inventory and the right amount of inventory. It can really take time to talk with retailers, Scott said.

(The archive of "magic boards" riden by team riders through the years. Sometimes current riders will go through the boards and find features they like, which will then be incorporated into their boards.)

Company founder and legendary shaper Al Merrick is still involved in Channel Islands as a consultant, and comes into the office a few times a week when he is in town. He recently helped shapers perfect a special kind of rail on a board, and also acts as company ambassador at events and with athletes.

Margin builders

Because hardgoods are notoriously low margin, and Burton has made a lot of infrastructure improvements, I did ask Scott how that all shakes out financially.

(Dane Reynolds' traction pads.)

He said one way the company is increasing overall margins is expanding into accessories and apparel, which are more profitable.

While the company has dabbled in the area in the past, over the past two years there has been a more concerted effort.

Channel Islands is now selling leashes and traction pads, with packaging designed by team rider Dane Reynolds.

It also is making board bags and some travel bags, including a lightweight board bag that attaches to a suitcase with wheels, thus eliminating the needs for wheels in the board bag. That offering goes to market in March.

With apparel, Channel Islands is making a very limited selection of T’s, fleece and hats, but doesn’t plan on becoming a full-blown apparel brand, Scott said.

Retail base

I asked Scott how Channel Islands’ customers have held up during the recession.

(Scott goes through new boards waiting to be picked up by team riders: "Here's Tanner's, Dusty's, Kelly's...)

“Not too bad,” he said, noting he could count on one hand the number that have closed.

But, the company has pretty narrow distribution, Scott said, about 100 to 120 accounts, all specialty accounts with a large hard goods offering. The biggest company accounts include Huntington Surf & Sport, Surfride, Jack’s and Surf Station.

Trends, hot sellers

Scott said board trends include the move to shorter, wider boards, which is being seen on tour and in board sales.

In fact, the short and wide Dumpster Diver, a Dane Reynold’s model, was the best selling board for Channel Islands last year, replacing the nine-year reign at the top for The Flyer.

A new Dane Reynolds model called the Neck Beard - the name is somehow related to San Clemente, though Scott did not want to go into details – will be released in April.

Other upcoming releases include:

A more environmentally friendly Rob Machado board called Motorboat, made with a Green Foam blank, UV cure and resin and a recycled fin, on Nov. 15.

( a drawing on Rob Machado's new Motorboat model.)

The Warp, a Shaun Tomson model, slated for January.

The Semi-Pro, a Kelly Slater model, also slated for January.

Remix from Dusty Payne in February.

And Cheese Stick from Yadin Nichol in March.

(The production office.)

The company also usually has special releases in summer and at holiday.

Staggering the releases helps shops manage inventory and creates excitement as surfers come in looking for something new, Scott said.

New Technologies

I asked Scott if there were any big new technological advances for surfboards on the way.

He said after the Burton acquisition, Channel Islands worked with Burton engineers to look at new advances in materials, manufacturing, recyclables, etc.

The end result, however, was that while they learned a lot during that process, Channel Islands boards are driven by its team of athletes. And the athletes are competing on the boards, and don’t really want wholesale change.

Instead, there will likely be incremental change – currently, some different fin and stringer materials are being tested, etc.

“You’re not going to put electric cars on NASCAR overnight,” he said.

Whole Foods/Amazing Grass Promotion

2010-10-08T10:17:00.000-07:00

Jason Mraz Is Turning the Tide: An Interview (Kid Natural Board Pictured)

2010-10-07T12:07:00.000-07:00

Jason Mraz Is Turning the Tide: An Interview

Gulf Coast

2010-10-04T18:22:00.000-07:00

Into the Blue - Features - Coast Magazine

2010-10-04T16:42:00.000-07:00

Into the Blue - Features - Coast Magazine

San Clemente surfboards - The West's most innovative cities - Photos - Sunset.com

2010-10-04T16:37:00.000-07:00

San Clemente surfboards - The West's most innovative cities - Photos - Sunset.com

Green Foam on Anderson Cooper

2010-06-17T14:19:00.000-07:00

KillerDana.com Interviews Green Foam

2010-06-04T17:51:00.001-07:00

Green Foam Sustainability

2010-06-04T17:50:00.000-07:00

Hans Hagen is Riding Green

2010-06-04T14:36:00.000-07:00

Here are a couple sequences Jack English snapped down in Mexico back in May. Hans is rocking a Green Foam blank in these photos. Do you have any images with your Green Foam board? Email them to us or upload them on facebook at http://facebook.com/greenfoamblanks

Aloha,

Joey

Win a Channel Island Green Foam Board

2010-05-28T02:27:00.000-07:00

Whole Foods has teamed up with Channel Island Surf Boards, Amazing Grass, and FCS Fins to offer you a chance at winning a free Channel Island Surf Board shaped from a Green Foam Blank.

Head to your local Whole Foods for details.

Article About Green Foam on CNN

2010-05-27T20:39:00.000-07:00

Recycling waste isn't a waste of time for surfboard form maker
By Paul Vercammen, CNN
STORY HIGHLIGHTS

* Joey Santley and Steve Cox sweep up polyurethene dust, make surfboard blanks
* Blanks are board-shaped foam cutouts that are finished at surfboard manufacturers
* About 40 percent of each surfboard blank winds up in the dump, Santley estimates
* Professional surfer says boards made with Green Foam just as good as others

To see the full story, click here.

Green Foam Featured on CNN!

2010-05-27T20:22:00.000-07:00

If you missed our feature on CNN you can see it here!

Cover of Have It Green Magazine

2010-05-26T11:10:00.000-07:00

Check out the bottom of the cover on the May issue of Have it Green magazine. Click on the image above to view an eco-friendly digital version of the magazine. Our story is on page 32.

Green Foam featured on VIMBY

2010-05-26T10:56:00.000-07:00

VIMBY - Green Foam

Green Foam Blanks and Resurf Foundation on Anderson Cooper 360!

2010-05-26T08:23:00.000-07:00

Green Foam Blanks and Resurf Foundation on Anderson Cooper 360!

There will be an expanded web version of the story that will run on CNN.com the following day. Please check it out and leave a comment.

Thanks for taking the time to think about the environment and our precious relationship with it. Please pass this on to any of your friends that might be interested.

Cheers!

Joey

US Blanks Exclusive License of Green Foam

2010-05-09T07:51:00.000-07:00

http://www.usblanks.com/news/pr03-24-2010.php

Green Foam Signs Exclusive Licensing Agreement with USBlanks

LOS ANGELES, CA - March 24, 2010

Green Foam and USBlanks are proud to announce that USBlanks is the new Exclusive Manufacturer, and Distributor of Green Foam in North America, Japan, Europe, and Costa Rica.

USBlanks, located in Gardena, California is the world's leading manufacturer of polyurethane and EPS surfboard blanks both domestically and internationally. Their forward thinking awareness to environmentally sound manufacturing processes and constant efforts to reduce their manufacturing footprint makes this a perfect union in stepping towards a "greener" future in surfboard production.

Green Foam, and the USBlanks' global distributors will work in concert to introduce Green Foam to their established markets world-wide. The world will now have easy access to high quality - Recycled Green Foam Blanks.

Green Foam blanks are made from recycled rigid polyurethane foam waste produced in manufacturing surfboards. Green Foam Blanks has patents pending on its proprietary technology and looks forward to pushing the limits eliminating the PU waste in the future. Green Foam uses a Cradle to Cradle process in reintroducing the waste back into the parent product.

"We are honored that USBlanks, the leader in surfboard blank production, is our new manufacturing partner and look forward to a creating a greener future for surfboard production." Said Joey Santley- Co Founder of Green Foam. "Partnering with Green Foam allows us to increase our established recycling abilities, which include PU and EPS foam scrap, paper, and wood. Our continual reduction in our waste footprint sets the standard for a greener blank manufacturing process worldwide.", says Kimberly Thress of USBlanks. If interested in ordering Green Foam blanks- Contact USBlanks directly.

About US Blanks- www.usblanks.com

USBlanks, LLC. was established in 2006 in an effort to bring quality surfboard blanks and unparalleled customer service back into a chaotic marketplace. In just 4 short years this strong partnership has grown into the leading manufacturer of polyurethane and EPS surfboard blanks worldwide. Their attention to quality, customer service and detail has propelled USBlanks to the forefront of a very competitive and ever changing market.

US Blanks
P.O. Box 486
Gardena, CA 90248
Phone: (310) 225-6774
Fax: (310) 225-6922
info@usblanks.com

Copyright © 2009 USBlanks

New York Times Article on Green Foam

2010-04-18T09:12:00.000-07:00

http://greeninc.blogs.nytimes.com/2009/11/19/sustainable-surfing-rides-the-waves/

Sustainable Surfing Rides the Waves
By TODD WOODY
A worker for Green Foam Blanks, a green surfboard manufacturer in San Clemente, Calif. J. Emilio Flores for The New York Times A worker for Green Foam Blanks, a green surfboard manufacturer in San Clemente, Calif.

As I wrote in a New York Times article on Thursday, the $7.2 billion surf business has become the latest industry to ride the green wave. Call it sustainable surfing.

Surfers, of course, have always been in tune with their environment, and groups like the Surfrider Foundation take on those who would desecrate beach and wave break. Out of mind for most surfers, though, has been the rather toxic business of making surfboards and the tons of waste generated from broken boards, old wetsuits and other cast-offs from the nature-boy lifestyle.

Green Foam Blanks, a San Clemente, Calif., company started by the surf industry veteran Joey Santley and Steve Cox, makes recycled polyurethane blanks – the foam core of surfboards. Polyurethane surfboards are made with a carcinogenic chemical compound, and Green Foam aims to reduce demand for new polyurethane by recycling the considerable amount of waste produced when shaping a surfboard from a slab of foam. Old surfboards can be recycled as well.

But Mr. Santley and Mr. Cox’s ambitions go beyond surfboards. Another of the duo’s ventures, ReSurf, is experimenting with using polyurethane waste and broken boards as a filler for asphalt paving as well as making surfboard accessories out of neoprene wetsuit waste.

Sitting in his truck across the street from the beach in San Clemente recently, Mr. Santley reached for a backpack and pulled out prototypes of sandals, a surfboard leash and a traction pad for surfboards called a deck – all made of recycled neoprene, a synthetic rubber.

“For the last 50 years, all this waste has been going straight to the landfill and still is today,” said Mr. Santley, 44, a surfer and longtime marketing executive in the surf industry.

Gary Petersen is a former member of the California Integrated Waste Management Board, a state agency that oversees recycling programs. “The surfboard industry does not produce the tens of millions of tons of waste annually as municipalities do, but it has significant impact with toxins,” said Mr. Petersen, who has been advising Mr. Santley.

Mr. Santley also hopes to tap the automotive market — he has sent samples of recycled polyurethane to Tesla Motors, the Silicon Valley electric-car maker, to be evaluated for use in dashboards. But Green Foam’s focus for now is on surfboards.

Since beginning production earlier this year, Green Foam has made about 1,000 blanks. A surf industry insider with connections to Hollywood and the music business, Mr. Santley has mounted a guerrilla marketing campaign to get recycled surfboards in the hands of celebrities, respected surfboard builders and pro surfers.

The actor Matthew McConaughey rides a Green Foam board as does the rocker Perry Farrell and the singer-surfer Jason Mraz. “I understand that humans have to learn to do more with less, therefore the products I use, like a surfboard for instance, I prefer to be made with our environment in mind,” Mr. Mraz wrote in an e-mail message.

Matt Biolos, a leading surfboard shaper and owner of Lost Enterprises in San Clemente, said that he had made 100 Green Foam surfboards so far and that he expected they could easily become 10 to 15 percent of his annual production of 8,000 boards. “The demand is surprising,” he said.

Green surfing products remain a niche market but a growing one, said Frank Scura, executive director of the Action Sports Environmental Coalition, an organization that promotes green retailing.

“Getting Green Foam used as much as possible in the supply chain will be Joey’s major challenge,” Mr. Scura said.

His group is working with Hobie and other surf industry retailers to create “Green Rooms” within their stores that sell sustainable products like board shorts made of recycled plastic and environmentally sensitive neoprene wetsuits. Mr. Santley will market Green Foam surfboards in the Green Rooms under his new “G” brand.

“I think sustainability represents a really perfect opportunity to tap that core rebellious tendency of surfers,” Mr. Scura said.

*
E-mail Th

LA TIMES -For eco-friendly surfboard shapers, more kelp in the lineup

2010-04-17T16:49:00.001-07:00

For eco-friendly surfboard shapers, more kelp in the lineup - latimes.com

Posted using ShareThis

Green Foam signs Exclusive Licensing Agreement with USBlanks.-

2010-03-24T08:49:00.000-07:00

San Clemente, CA, 3/18/2010- Green Foam and USBlanks are proud to announce that USBlanks is the new Exclusive Manufacturer, and Distributor of Green Foam in North America, Japan, Europe, and Costa Rica .

FOR IMMEDIATE RELEASE

PR Log (Press Release) – Mar 24, 2010 – San Clemente, CA, 3/18/2010- Green Foam and USBlanks are proud to announce that USBlanks is the new Exclusive Manufacturer, and Distributor of Green Foam in North America, Japan, Europe, and Costa Rica . USBlanks, located in Gardena, California is the world’s leading manufacturer of polyurethane and EPS surfboard blanks both domestically and internationally. Their forward thinking awareness to environmentally sound manufacturing processes and constant efforts to reduce their manufacturing footprint makes this a perfect union in stepping towards a “greener” future in surfboard production.

Green Foam, and the USBlanks’ global distributors will work in concert to introduce Green Foam to their established markets world-wide. The world will now have easy access to high quality - Recycled Green Foam Blanks.

Green Foam blanks are made from recycled rigid polyurethane foam waste produced in manufacturing surfboards. Green Foam Blanks has patents pending on its proprietary technology and looks forward to pushing the limits eliminating the PU waste in the future. Green Foam uses a Cradle to Cradle process in reintroducing the waste back into the parent product.

“We are honored that USBlanks, the leader in surfboard blank production, is our new manufacturing partner and look forward to a creating a greener future for surfboard production.” Said Joey Santley- Co Founder of Green Foam. “Partnering with Green Foam allows us to increase our established recycling abilities, which include PU and EPS foam scrap, paper, and wood. Our continual reduction in our waste footprint sets the standard for a greener blank manufacturing process worldwide.”, says Kimberly Thress of USBlanks. If interested in ordering Green Foam blanks- Contact USBlanks directly.

About US Blanks- www.usblanks.com
USBlanks, LLC. was established in 2006 in an effort to bring quality surfboard blanks and unparalleled customer service back into a chaotic marketplace. In just 4 short years this strong partnership has grown into the leading manufacturer of polyurethane and EPS surfboard blanks worldwide. Their attention to quality, customer service and detail has propelled USBlanks to the forefront of a very competitive and ever changing market.

About Green Foam- www.greenfoamblanks.com
Green Foam was established in 2009 to bring recycling to the blank manufacturing process. A primary goal was to produce a first (1st) quality blank to rival any blank on the market while having a smaller impact on the environment. Green Foam keeps the foam waste from going into our landfills and gives it another chance to ride. Green Foam can be recycled over and over and over again. Founders Joey Santley and Steve Cox also co-founded the ReSurf Foundation – a non profit organization dedicated to educating the Surf Industry about reducing, reusing and recycling the waste produced in manufacturing products sold in the surf market. www.resurf.org
# # #

About Green Foam- www.greenfoamblanks.com
Green Foam was established in 2009 to bring recycling to the blank manufacturing process. A primary goal was to produce a first (1st) quality blank to rival any blank on the market while having a smaller impact on the environment. Green Foam keeps the foam waste from going into our landfills and gives it another chance to ride. Green Foam can be recycled over and over and over again. Founders Joey Santley and Steve Cox also co-founded the ReSurf Foundation – a non profit organization dedicated to educating the Surf Industry about reducing, reusing and recycling the waste produced in manufacturing products sold in the surf market. www.resurf.org

To embed this press release, copy and paste the following HTML code into your webpage-

# # # + Share This + Embed This

Email to a Friend

Email Contact : Click to email (Partial email = @gmail.com)
Issued By : Joey Santley- Green Foam
Phone : 949-542-0464
Fax : 516-345-2516
Address : 1001 Ave Pico C204
Zip : 92673
City/Town : San Clemente
State/Province : California
Country : United States
Categories : Consumer, Lifestyle, Science
Tags : eco, Green, surfboards, blanks, recycle, environment, sustainable, earth, foam
Last Updated : Mar 24, 2010
Shortcut : http://prlog.org/10592282

Surfing's newest trick: recycling | santley, recycled, foam - News - The Orange County Register

2010-03-13T11:23:00.001-08:00

Surfing's newest trick: recycling | santley, recycled, foam - News - The Orange County Register

Posted using ShareThis

San Clemente surfboards - The West's most innovative cities - Photos - Sunset.com

2010-03-03T08:05:00.000-08:00

San Clemente surfboards - The West's most innovative cities - Photos - Sunset.com

San Clemente one of 20 'innovative' places to live | surfboard, sunset, recycling - News - The Orange County Register

2010-03-03T08:04:00.001-08:00

San Clemente one of 20 'innovative' places to live | surfboard, sunset, recycling - News - The Orange County Register

Posted using ShareThis

Business of Green - Green Foam Blanks Tries to Limit Toxin From Making Surfboards - NYTimes.com

2009-11-26T07:04:00.000-08:00

Business of Green - Green Foam Blanks Tries to Limit Toxin From Making Surfboards - NYTimes.com

Green Foam Blanks’ Environmental Efforts | Transworld Business

2009-11-26T07:01:00.000-08:00

Green Foam Blanks’ Environmental Efforts Transworld Business

Jason Mraz rides G board made with Green Foam

2009-11-06T19:15:00.001-08:00

San Clemente Times video

2009-10-04T08:21:00.000-07:00

http://www.youtube.com/watch?v=9Bva55koBig

Orange Coast Magazine Joey Santley August 2009

2009-08-17T11:27:00.001-07:00

Surfing the Green Issue Aug 2009

2009-08-17T11:26:00.001-07:00

Shop Eat Surf Update

2009-06-29T09:48:00.001-07:00

What's next for Green Foam and its business April 13, 2009 06:45 AM

Joey Santley in the ...lost shapers factory, with foam dust.

Updated May 2 at 10 a.m. The other day, I heard from Joey Santley, who said that ...lost is now in production on boards for sale at retail from Green Foam blanks. Joey's note said that the boards are mostly Thrusters. Here's part of what Joey posted on Green Foam's Facebook page this week: Lost Surfboards is in production of Green Foam stock boards! Ask your local retailer/ shaper for some Green Foam in your next board - because you care about your impact on the world and want to be part of the solution and not the problem.

By ANDREW HORAN

In the months since we first told you about Green Foam and the debut of its first production recycled surfboard at the opening day of the January ASR show, Joey Santley and Steve Cox have been getting lots of pub and love - and some business, too.

I checked back with Joey to see how things are going, who's getting the boards, and what's next. After popping into the shaper's bay behind Catalyst Surf Shop on San Clemente's North Beach, we hopped into Joey's truck and headed over to Shaper's Alley to see some Green Foam blanks, finished boards - and bags and bags of shapers' dust set aside for Joey and Steve to collect and recycle.

Pros get theirs first

Green Foam blanks stacked up after being blown at Just Foam.
This and next three photos courtesy Green Foam.

About 500 boards have been built from Green Foam's recycled blanks so far, and they've gone to pro surfers or celebrities. Except that very first one, which was shaped by Matt Biolos and donated to the Surfing Heritage Museum in San Clemente.

Green Foam blanks are blown by Just Foam in Oceanside, and they're available for any shaper to use for a custom board now. Joey said he hopes to make them more widely available at retail in coming weeks.

As with most products in the industry, Green Foam is hoping to gain acceptance and word-of-mouth approval from core surfers and shapers, and use that goodwill to build a business.

"We're waiting for the wave of public consciousness to happen," Joey told me. "The best way to get that is to get our friends who are the best surfers in the world to try them. When you see pictures and videos of the pros riding them, that's the stamp of approval.

"They have the power, they can help us create a whole shift in the way a whole industry does things."

So far, Joey says boards shaped from Green Foam blanks have gone to pros Chris Ward, Cory Lopez, Hans Hagen, Dustin Barka, Coco Ho, Kasey Curtis, Christian Fletcher, Shea Lopez, Hopper Eichstaed. And to celebrities Cameron Diaz, Matthew McConaughey and Perry Ferrell.

Shapers

He has fans in the ...lost factory. Matt Biolos, Darryl Butsko and Dev have shaped boards from his blanks.

While we were talking near the racks in ...lost's factory, a few shapers stopped to say hello and needle Joey. "Picking up the trash?" Dev teased on his way out the back door.

He came back in to give Joey specs for making the blanks even more workable. He and Darryl told me the recycled blanks are as easy to work as virgin blanks. What would make them use more recycled blanks? Simple - if customers ordered more.

Joey Santley and Steve Cox with Scott Saunders and
Sid Shneider of Just Foam. Scott is the owner
of Just Foam and Sid is the engineer.

"Over time, a lot of people will be willing to accept it," Dev said. "Some won't."

Those shapers have helped Green Foam refine its product. For instance, they're using only the finest dust that's a byproduct of shaping with power planers. The ...lost factory is setup to vacuum that dust into bags, which are set aside for Joey and Steve to collect.

Gradually, the blend has changed. Green Foam's blanks are now about 60 percent recycled dust to virgin polyurethane. That's about all Joey will reveal about the process of getting the dust to bond with the virgin foam to create a shapeable blank.

But Dev and Darryl seem to think Green Foam has it right. They both told me that the blanks have all the same qualities as 100 percent virgin foam blanks. Joey says they produce a board equally as durable as virgin foam boards.

Picking it all up

All of this is a labor of love.

Joey Santley, Steve Cox.

Joey and Steve pick up bags of discarded blank waste from shapers. Some bags are filled with about 50 pounds of fine dust that will be blended with new foam and recycled into new board blanks.

One 50-pound bag of dust from a factory will make about 25-30 boards, depending on the size of the blanks.

Other bags are stuffed with big chunks of foam, stringers and wasted resin that they grab for another purpose: road building. "Most of the waste from surf factories can be ground up and mixed into asphalt and concrete as an additive," Joey says.

Joey and Steve have worked out a method to recycle and reuse neoprene used to make wetsuits, and have a pilot program underway with Quiksilver and O'Neill to collect and reuse neoprene scraps.

Here's how he explains it: "We have figured out how to recycle the neoprene waste cuttings from wetsuit manufacturing. We process the material much like you would carpet padding.

"We take the scraps and chop/grind them into very small pieces that we reintroduce into new 'buns' using some virgin raw material to pull it back together. We then can slice the bun into any thickness from a roller machine - kind of like peeling a potato.

"The bun spins and a knife cuts the appropriate thickness for whatever application the material will be used for. We will be making things like yoga mats, backpack inserts and many other applications once we get up and going."

Next up: They want to take their board and wetsuit recycling ideas to Hawaiian manufacturers. They want to expand to South Africa, Australia, Japan. And they're hoping to land a sponsor to underwrite their expansion.

ESPN Article

2009-06-29T09:46:00.001-07:00

The Origin of the Surfboard

As you ponder your new summer stick, think green. The recycled surfboard may be on the rack sooner than you think.

March 11, 2009, 9:26 PM

By: Jake Howard

: Howard

Howard

The stamp says it all. Make your next board a recycled board.

Up until I walked into Just Foam, I'd never been to a surfboard blank factory. I'd seen plenty of raw, half-made surfboards, but never witnessed the foam actually being produced. The closest I'd been was when Clark Foam closed down and every surf publication dutifully ran images of sledgehammered molds mournfully cast out in an Orange County back alley.

Several weeks prior to my foam factory experience, I'd gotten an email from the publicist for Green Foam, and while not one to usually pursue such obvious sales pitches, when the words "recycled surfboard" came up, I curiously conceded. That's how I came to know Joey Santley, one of the masterminds behind Green Foam.

I talked to him briefly on the phone. He lives in San Clemente, I live in San Clemente, we agreed we'd probably dropped in on one another at Lowers at some point, then set a date to meet at the factory.

"After the fall-out from Clark Foam and the experimentation with materials that followed, if we've gotten to a point where PU foam blanks are still the material of choice, then why not try to make them better?" Joey theorized, greeting me in a dim, foam-dusted front entryway. "If part of making something better means making it more friendly for the environment, then repurposing the wasted foam from shaped blanks—essentially grinding the foam up and re-blowing it—is a no brainer. Right now 25% of a pre-shaped blank ends up in a landfill. For the first time ever, now we can turn all that stuff that would normally just be thrown out into new, grade-A blanks."

Howard

Holding the first-ever recycled surfboards, partners in Green Joey Santley and Steve Cox have a lot to be smiling about.

Walking into the proverbial light, we opened up into the heart of the factory. Hundreds of virgin blanks were stacked and racked from concrete floor to steel rafters. You could almost hear the hymns of the surfboard angles reverberating off the tin roof...or it might have been the rain.

"The guys are in the back right now looking at the latest batch," said Joey. The "guys" he was talking about was Green Foam co-conspirator Steve Cox, along with Just Foam's S.L. "Sid" Shneider, who's been instrumental in getting all of this off the ground.

Steve popped out of a mystery door. "This latest batch is really clean," he said, smiling at Joey. "Come and look...but the reporter has to stay."

I felt like C3PO trying to get into the cantina bar in Star Wars. He may as well have called me a droid. "He can come," said Joey, sticking up for me.

"Here, come check it out. But it's top secret, so you can't talk about what you see back here," he warned, inferring I was the kid that betrayed the secret of the ever-lasting Gobstopper.

Courtesy Green Foam/Photo Seth

Green surfboard, green room. Some captions just write themselves. Teamrider Hopper Eichstaed, planting the seed.

Steve and Joey cackled back and forth, switching between chemist and surfboard-speak. I moseyed along, trying to forget what I was seeing, which wasn't that hard because I didn't really know what any of it was anyway. We came to a florescent light box, where Sid was inspecting a gleaming white blank.

He was looking for particles of chopped up stringer, little sinkholes, and other imperfections. "This is as good of quality as you're going to get with any blank in this entire factory," said Sid.

Helping me understand more of what they were looking at, Joey explained how when you grind up surfboard waste—stuff like foam castaways, stringers and glue—and reuse it you get a grainier, more organic look to the blank. "Surfers are so stuck on having that brand-new, white surfboard, if they can get past that weird mental block, I think the surfboard business can become much more green."

"The only effect any of this 'pulp' material has is purely aesthetic," said Steve. "Based on feedback from guys who have shaped the blanks—Matt Biolos, Timmy Patterson, and Rusty—the particles didn't remotely hinder the boards being made. Planners and sanders didn't catch or skip or anything, just like shaping a normal blank."

It's still early days for the boys at Green Foam, and there's sure to be the odd hiccup here and there as the volume of what they're doing starts to increase, but they're undoubtedly on to something. The first time the public was privy to what they've been doing was when they debuted the blanks at the ASR trade show in San Diego back in January, and for now they've just been trying to get the blanks in the hands of the shapers.

"We're really fortunate to have some great shapers nearby," said Joey, as we walked out of "the lab" and began a tour of the facility. "I can be on my way home from work and drop a blank off with Matt or Timmy and they can have a go at it and tell me what they think. Al Merrick and Rusty have both shaped the blanks, and I think if we can get to a point where people like that are supporting and believing in what we're doing, we can go a long way with this."

Courtesy Green Foam

The engrineer of the group, Just Foam's S.L. "Sid" Shneider.

In the words of Jerry McGwire, "You had me at hello." But as impressed as I was with what they were saying, I still had questions. The boards had to be more expensive, right?

"Nope," answered Steve, "it's the same price as a normal blank. We don't want to penalize people for doing the right thing."

OK, sweet. Well, then what about how many times you can recycle foam? Surely there's a limit. "We know it can be done at least three or four times, and probably more," answered Steve again.

I was now officially a believer. In fact, by the time I left, I was not only converted, I reckon every batch of boards I get from here on out is going to be recycled.

"We're extending the life of surfboards," said Joey, as we stood out front of Just Foam, my mind thoroughly blown. "We thought about the cradle-to-grave concept and how we can apply it to surfboards, and right now we're confident this is the best thing going."

I still had one more question. "Does this mean I can bring in all those crappy, old boards I have behind the house and recycle them now, like I do with my newspaper or motor oil?"

"Pretty much," said Joey. "It's a little more complicated than that, but that's a goal."

Howard

This could be your next batch of boards, eco-sensitive and everything.

Hans Hagen surfing creek

2009-04-27T18:54:00.001-07:00

Green Foam in production at ...Lost

2009-04-27T18:45:00.000-07:00

donovan frankenreiter Surfs on his new green foam boards shaped by DOC naki photo

2009-03-29T17:10:00.001-07:00

Xanadu shapes green foam for Hans Hagen

2009-03-22T17:25:00.000-07:00

EXPN Article

2009-03-13T08:19:00.000-07:00

Green surfboard, green room. Some captions just write themselves. Teamrider Hopper Eichstaed, planting the seed.

The Origin of the Surfboard
As you ponder your new summer stick, think green. The recycled surfboard may be on the rack sooner than you think.
March 11, 2009, 9:26 PM
By: Jake Howard

Howard

Howard
The stamp says it all. Make your next board a recycled board.Up until I walked into Just Foam, I'd never been to a surfboard blank factory. I'd seen plenty of raw, half-made surfboards, but never witnessed the foam actually being produced. The closest I'd been was when Clark Foam closed down and every surf publication dutifully ran images of sledgehammered molds mournfully cast out in an Orange County back alley.
Several weeks prior to my foam factory experience, I'd gotten an email from the publicist for Green Foam, and while not one to usually pursue such obvious sales pitches, when the words "recycled surfboard" came up, I curiously conceded. That's how I came to know Joey Santley, one of the masterminds behind Green Foam.
I talked to him briefly on the phone. He lives in San Clemente, I live in San Clemente, we agreed we'd probably dropped in on one another at Lowers at some point, then set a date to meet at the factory.
"After the fall-out from Clark Foam and the experimentation with materials that followed, if we've gotten to a point where PU foam blanks are still the material of choice, then why not try to make them better?" Joey theorized, greeting me in a dim, foam-dusted front entryway. "If part of making something better means making it more friendly for the environment, then repurposing the wasted foam from shaped blanks—essentially grinding the foam up and re-blowing it—is a no brainer. Right now 25% of a pre-shaped blank ends up in a landfill. For the first time ever, now we can turn all that stuff that would normally just be thrown out into new, grade-A blanks."

Walking into the proverbial light, we opened up into the heart of the factory. Hundreds of virgin blanks were stacked and racked from concrete floor to steel rafters. You could almost hear the hymns of the surfboard angles reverberating off the tin roof...or it might have been the rain.
"The guys are in the back right now looking at the latest batch," said Joey. The "guys" he was talking about was Green Foam co-conspirator Steve Cox, along with Just Foam's S.L. "Sid" Shneider, who's been instrumental in getting all of this off the ground.
Steve popped out of a mystery door. "This latest batch is really clean," he said, smiling at Joey. "Come and look...but the reporter has to stay."
I felt like C3PO trying to get into the cantina bar in Star Wars. He may as well have called me a droid. "He can come," said Joey, sticking up for me.
"Here, come check it out. But it's top secret, so you can't talk about what you see back here," he warned, inferring I was the kid that betrayed the secret of the ever-lasting Gobstopper.

Steve and Joey cackled back and forth, switching between chemist and surfboard-speak. I moseyed along, trying to forget what I was seeing, which wasn't that hard because I didn't really know what any of it was anyway. We came to a florescent light box, where Sid was inspecting a gleaming white blank.

He was looking for particles of chopped up stringer, little sinkholes, and other imperfections. "This is as good of quality as you're going to get with any blank in this entire factory," said Sid.
Helping me understand more of what they were looking at, Joey explained how when you grind up surfboard waste—stuff like foam castaways, stringers and glue—and reuse it you get a grainier, more organic look to the blank. "Surfers are so stuck on having that brand-new, white surfboard, if they can get past that weird mental block, I think the surfboard business can become much more green."

"The only effect any of this 'pulp' material has is purely aesthetic," said Steve. "Based on feedback from guys who have shaped the blanks—Matt Biolos, Timmy Patterson, and Rusty—the particles didn't remotely hinder the boards being made. Planners and sanders didn't catch or skip or anything, just like shaping a normal blank."

It's still early days for the boys at Green Foam, and there's sure to be the odd hiccup here and there as the volume of what they're doing starts to increase, but they're undoubtedly on to something. The first time the public was privy to what they've been doing was when they debuted the blanks at the ASR trade show in San Diego back in January, and for now they've just been trying to get the blanks in the hands of the shapers.
"We're really fortunate to have some great shapers nearby," said Joey, as we walked out of "the lab" and began a tour of the facility. "I can be on my way home from work and drop a blank off with Matt or Timmy and they can have a go at it and tell me what they think. Al Merrick and Rusty have both shaped the blanks, and I think if we can get to a point where people like that are supporting and believing in what we're doing, we can go a long way with this."

In the words of Jerry McGwire, "You had me at hello." But as impressed as I was with what they were saying, I still had questions. The boards had to be more expensive, right?
"Nope," answered Steve, "it's the same price as a normal blank. We don't want to penalize people for doing the right thing."
OK, sweet. Well, then what about how many times you can recycle foam? Surely there's a limit. "We know it can be done at least three or four times, and probably more," answered Steve again.
I was now officially a believer. In fact, by the time I left, I was not only converted, I reckon every batch of boards I get from here on out is going to be recycled.
"We're extending the life of surfboards," said Joey, as we stood out front of Just Foam, my mind thoroughly blown. "We thought about the cradle-to-grave concept and how we can apply it to surfboards, and right now we're confident this is the best thing going."
I still had one more question. "Does this mean I can bring in all those crappy, old boards I have behind the house and recycle them now, like I do with my newspaper or motor oil?"
"Pretty much," said Joey. "It's a little more complicated than that, but that's a goal."

Howard
This could be your next batch of boards, eco-sensitive and everything.

SC Times Article

2009-02-23T09:20:00.000-08:00

Recycling an Industry

one-two punch, as defined by The American Heritage Dictionary
can either be; 1. A combination of two blows delivered in
rapid succession as in boxing, especially a left lead followed
by a right cross; or 2. An especially forceful or effective combination
or sequence of two things. Both definitions seem especially fitting
analogies for the two-tiered effort of Joey Santley and Steve Cox
to “green up” the surf industry by providing a means for recycling
wetsuit scrap, old boards and the waste created during the production
of new ones. As co-founders of San Clemente-based Green
Foam Blanks and ReSurf Recycling, they have essentially proven
the feasibility of a closed-loop environmentally conscious system for
the manufacture and recycling of surfboards and wetsuits.
“The surf community now knows that there’s an option to go
green,” said Santley. “Most surfers care deeply about the environment
and given the opportunity to choose a green alternative they
will make the right choice,”
Part one of the plan began
with the launch of ReSurf
Recycling in late 2007.
ReSurf was created as a
philanthropic effort aimed
at cleaning up the industry
by organizing a network of
drop-off and pick-up locations
for the collection of
reusable “surf waste.” By
recycling old surfboards as
well as the hazardous waste
created during the shaping of new boards, tons of polyurethane
need not end up in landfills. Because surf waste is a petroleum
bi-product it is essentially hazardous but for this same reason it
also bonds perfectly with asphalt and concrete. ReSurf invented a
process of re-purposing discarded surfboards and waste into asphalt
and concrete for paving roads. A pilot program is in the works with
CR&R and Waste Management to provide surf waste specific trucks
to make the rounds from surf shops to shaping rooms collecting the
material specifically for use in paving. In addition to the invention of
a use for board scrap the company has also come up with a method
for producing 100 percent recycled yoga mats from the neoprene
scrap generated by wetsuit manufacturers.
The second part of the plan came to fruition when Santley and
Cox teamed up with Sid Schneider and Scott Saunders of Oceanside-
based foam manufacturer Just Foam to create the first recycled
polyurethane surfboard blank. What was once considered to be
impossible became a reality when the first recycled blank came
out of the mold on November 11. Matt “Mayhem” Biolos of Lost
Surfboards had the honor of shaping that first board which is now
part of the collection housed at the Surfing Heritage Museum in
San Clemente. Testing by shapers and surfers alike has confirmed
the blanks are equal to traditional blanks in the areas of high-performance,
durability and strength-to-weight ratio.
Santley and Cox introduced their plan to a very receptive industry
A
Courtesy photo
Local company offers a new, green approach
crowd at the Action Sports Retailer trade show held last month
in San Diego. With the support of some of the top shapers in the
industry, seven boards made with Green Foam were on display. Lost,
Rusty, Al Merrick, T. Patterson, Surf Prescriptions, Wellen and Rawson
all participated in the shaping of these first-of-their-kind boards.
Their tradeshow debut resulted in commitments from more than 25
retailers to begin offering boards made from Green Foam, as well
as numerous inquiries by shops and shapers to become collection
points for scrap materials. O’Neill and Quiksilver have also agreed to
forgo dumping neoprene scrap and to instead donate it for recycling.
With the introduction of Green Foam and ReSurf a shift is apparent
as the industry begins to view surf waste as a resource. With an
estimated 250 tons of scrap neoprene and nearly three quarters of a
million surfboards produced annually the surf industry contributes
greatly to the problem of hazardous waste. “We know that it’s going
to be a lot of hard work,” said Santley. “But we will continue to push
the industry into taking steps toward sustainability to reduce our
carbon footprint in every way possible.” SC
ON THE WEB: www.resurf.org, www.greenfoamblanks.com

Shea Lopez and Hopper Reporting In

2009-02-19T17:16:00.000-08:00

OC Register Article Feb 9, 2009

2009-02-09T16:25:00.000-08:00

Monday, February 9, 2009
Billabong wasn't a
no-show at trade
show
Corky Carroll
Surf's Up columnist
The Orange County Register
corkysurf@aol.com

Last week I was telling you about my day at
the Action Sports Retailer (ASR) trade show
in San Diego. This is where the companies
involved in the action sports industry show
off their new products.
I mentioned that I was amazed that some of
the biggies in the surfing industry did not
attend this year and one of them was
Billabong. Well I was wrong on that one --
they were there and I just somehow missed
them. This is not surprising as I am a total
geek at these shows.
Anything catches my eye, possibly the butt
floss sting bikini booth or something, and I
walk right past six other things. Anyway,
Billabong is one of the main surf wear
companies and it is good to know that they
were there after all. It shows their good
support for an industry that is feeling the
effects of this recession severely. Good on
ya Billabong.

Also I was talking about the new products
that did get my attention. Another one was
the booth showing the new "green foam"
surfboard blanks. These two dudes Joey
Santley and Steve Cox have figured out a way
to produce usable surfboard foam made
from the foam dust and small pieces of
previously considered waste from shaping
room floors.

So instead of toxic waste we have more
surfboards. Very very extremely cool. They
estimate that normally about 20 percent of
the foam blanks used to make surfboards
ends up as waste and winds up in landfills.
Their company is called ReSurf Recycling and
its mission is to help clean up the surfing
industry.

They have another project in the works to
make "green" wetsuits from the same wasted
rubber left over in the production of surfing
wetsuits. This just backs up the old theory

Billabong wasn't a no-show at trade show one, surfing, time, industry, waste - News - O... Page that "one man's waste is another man's
treasure." One day you might be riding a
surfboard and wearing a wetsuit made totally
out of recycled materials. You will be ripping
and warm and at the same time saving the
planet.

Another cool product I saw was the
Goofboard. These things are kind of like the
old "Bongo Board" or the current "Indo
Board," which are basically pieces of wood
that roll back and forth over a rounded block
of wood that resembles a roller. Really fun
and a great way to break your neck at the
same time, what could be better than that?
Well the Goofboard is a bit different in the
fact that they roll on a cylinder that can be
placed either horizontally under the board or
vertically, thusly allowing a truer surfing feel.
My son Tanner tried it out and was stoked.
He wanted to see me do it but I am not real
fond of doing face and/or butt plants in
public -- especially surfing public. It's
embarrassing enough when I surf these
days, but at least then the water is a soft
landing.

Wow, not to change the subject in mid
column, but while writing this I just got an
email from my old pal and long time surfing
partner Mike Doyle. Mike is one of the alltime
great surfing legends and one of those
dudes who has kept himself in great shape
into his golden years when if he stuck to the
program like most of the rest of us he would
be fat and feeble.
But nooooo. He looks like he is in his 40's
and actually is in his late 60's. He still surfs
all the time as well and is a great skier and
snowboarder. He just sent me a bunch of
photos from Joey Cabell's 70th birthday
party up in Aspen, Colo. Amazing. I can't
believe Joey is 70. This is yet another of
those dudes who refuse to blend in and is
still shredding waves and mountains.
Joey was one of the top surfers in the world
during the 1960's and 70's and also a worldclass
skier. He was one of the original four
guys who started the Chart House restaurant
chain. The first ones were in Aspen and here
in Newport Beach.

Former World Surfing Champion Nat Young
is also in the photos and looks sleek too.
What's up with these guys? One of these
days I am gonna have to drop the chalupa I
guess. But geeze, I love food.

SURFING's Stuart Cornuelle checks in after ASR with his take on recycled surfboards

2009-02-06T20:19:00.001-08:00

Full disclosure: I wasn’t at ASR. Condolences to anyone who was. The physical wounds heal quickly, sure - calloused hands from high-fiving and a slight ringing in the ears. But the mental trauma of the trade show fades only with time.
Still I’m going to comment on it as though I were there. In my opinion, the best thing to see at ASR this year was booth #1036 and the debut of Green Foam Blanks, whose highly-touted answer to the pending doom of Earth is recycled surfboards. By partnering with Just Foam, a blower in Oceanside, these greentrepreneurs* now provide a 65% recycled foam blank. Using the scraps from shaping bays and CAD machines, they mix a proprietary foam blend that Matt Biolos, Rusty and Channel Islands have all been caught fooling around with. Saucy.
But the Holy Grail of sustainable production is a “closed loop system,” or one in which the product can, at the end of its useful life, be seamlessly reintroduced as an input in the next production process. This way resources can be passed around like a good book that’s purchased only once but enjoyed by many readers (i.e. rubber becomes tires become shoes become building insulation…). So the founders of Green Foam Blanks are also recycling old surfboards for use in, among other things, asphalt as road pavement. If you surf and aren’t some sort of a villain, like The Joker, then this is amazing news. Even though surfers try to act environmental and groovy sometimes, the manufacturing of boards and wetsuits is a real Sally Hemmings in our closet. How exciting that we can finally clean up the act. And I saved the best part for last: the blanks from Green Foam have ground-up stringer bits in them that give the boards a peppery look all their own - like when Firewires first came out and the lamination was that unsettling medium between polyurethane translucence and epoxy white. Really awkward. It was like a black eye on prom night, but they owned it, and now you know a Firewire from a hundred yards off and think, “Hey, that’s a Firewire. Wow. I think more highly of its owner now.” So maybe recycled blanks will have that same effect.
- advertisement -

*Portmanteau: a word or morpheme whose form and meaning are derived from a blending of two or more distinct forms. “Greentrepreneurs,” for instance, is a mix of Green and Entrepreneurs. It’s a fantastic portmanteau - it is portmantastic.
For more from Stuart, visit his blog at http://www.actionsportsgroup.net/blog/surfing

The Alternative Consumer it's a lifestyle thing

2009-02-06T19:58:00.001-08:00

Tuesday, February 3, 2009
The Next Wave: Recycled Surfboards
by Sylvia @ 9:08 am post a comment »

Plastic, paper, and surfboards? Attention surfers: your old, beat-up surfboard can now help pave the very road you drive on, or better yet, be given a second life as a recycled surfboard. ReSurf Recycling and Green Foam Blanks, two Southern California based organizations, have developed new methods in recycling what was long believed to be an unrecyclable material, “polyurethane.”
Of the 750,000 surfboards produced annually, an overwhelming majority is comprised of “polyurethane” foam – a not so eco-friendly material. During its production process, toxic chemicals, carbon dioxide, and volatile organic compounds are released into the atmosphere. And, 20% of the foam is rendered waste after custom shaping. Until recently, the foam was presumed to be unrecyclable, accumulating in landfills and producing heaps of waste.
At ReSurf Recycling, these discarded surfboards are transformed into asphalt or concrete and can be used to pave city roads. Old wet suits are also being recycled into yoga mats, helping to reduce the estimated 250 tons of waste created from neoprene wet suit scraps each year. Want to do your part and donate your old surfboard? With recycling facilities located throughout southern California, click here to find a location near you.
Green Foam Blanks teamed up with foam manufacturer Just Foam Blanks to create the first-ever recycled polyurethane surfboard blank. Patent-pending technology is responsible for making the once considered impossible a reality. And, don’t let the recycled part fool you; these boards are proving to measure up to modern surfboards in durability, lightness and function alike, just without the waste. Want to know where you can get one? Green Foam Blanks are manufactured at Just Foam in Oceanside, California, and have also been provided to surfboard manufacturers including Matt Biolos, Channel Islands, Rusty, Doc, Timmy Patterson and Pat Rawson.
Buy recycled, and surf’s up!

treehugger article

2009-02-06T19:55:00.000-08:00

Resurf: First Group to Recycle Surfboards and Wetsuits
by Kristin Underwood, San Diego, CA on 02. 6.09
Travel & Nature (sports gear)

Image via: ReSurf Recycling
So you hit a gnarly wave and end up on shore with your board in two pieces. Bummer dude. But your green side can't bear to just trash that board that's gotten you through some pretty wild rides. You could repair it yourself, but don't really know how. Never fear, ReSurf Recycling in Oceanside, CA will both take your old, broken boards and turn them into things like asphalt for roads. But now you need a replacement, right? Well, Green Foam Blanks will sell you a "new" blank made from 60% recycled foam, which you can take to your local shaper and make into your own custom board.

Surfing veterans Joey Santley and Steve Cox, developed ReSurf Recycling and Green Foam Blanks to help close the loop on toxic materials in surfing (i.e. the boards) that just end up in trash cans and to offer gear that makes use of stuff already in the waste stream.
Why Use a Recycled Surfboard?

Roughly 1,000 surfboards are made every day between Los Angeles and Mexico. 20% of the foam used to make these boards is ultimately scrapped, creating a giant waste stream, not to mention the toxic products used to cure the boards. ReSurf Recycling, launched in 2007, decided that the surfing community, already in touch with nature and the environment, would support an endeavor to cleanup this waste and launched their organization to close all of the open loops. ReSurf will recycle used boards, the scrap foam from manufacturing and even thrashed neoprene wetsuits. ReSurf recently partnered with O'Neill and Quicksilver to recycled the unused neoprene wetsuit scraps (an estimated 250 tons across the industry) into 100% recycled yoga mats.

So a recycled board might be good for the planet, but will it actually hold up? Yep, the boards are durable and cost-competitive with traditional boards on the market. Groups like ...Lost Surfboards, Channel Islands, and Surf Prescriptions are all using them. Shaper Matt "Mayhem" Biolos of ...Lost Surfboards said,

When I first saw the recycled blanks, they reminded me of when recycled paper first came out, it was a bit rough, but got the job done all while saving resources and lessening waste. The blanks are a tad coarse with some imperfections and take a bit of savvy to finish sanding them, yet for the most part the strength to weight ratio is on target. The specks of stringer and colored glue dust adds character and defines their look. Starting immediately, we will offer Green Foam Blanks to anyone who wishes to get a board made.
Boards that still have some life in them, but are donated, are refurbished and then given to Surfers Healing, which takes kids with autism out surfing. Dropoff Locations are available throughout Southern California for broken or old surfboards. If you're interested in becoming a board drop-off location, you can contact ReSurf to be listed among the locations and to get an official sticker. :Resurf :Green Foam Blanks

Earth911.com

2009-02-03T09:58:00.001-08:00

Surfboard Recycling Gets a Boost in CA
by Jennifer Berry
Two new organizations, ReSurf Recycling and Green Foam Blanks, are teaming up to help find new ways to reuse the toxic waste created from surfboard manufacturing. Business partners and surf industry veterans, Joey Santley and Steve Cox, are heading up the endeavors to help reduce landfill waste from the surfing industry.
According to the organizations, “more than 1,000 surfboards being produced per day between Los Angeles and the Mexico border. Additionally, nearly 20 percent of the foam needed to shape each board is rendered as waste and inevitably ends up in landfills.”
ReSurf
ReSurf Recycling launched in 2007, offering the first method to recycle all surfboards and waste associated with their manufacturing. The organization has “developed a method that recycles somewhat hazardous surfing-associated materials into numerous products including asphalt for paving city roads.”
Additionally, the organization developed a method to produce 100 percent recycled yoga mats made using neoprene scraps from wetsuit production. Big players in the industry are already joining in, as popular wetsuit manufacturers O’Neill and Quiksilver will be recycling all of domestic unused materials through this program.
Cox, co-founder of the company, said “ReSurf Recycling has literally invented a system of transforming discarded surfboards and previously unusable waste into asphalt and concrete that can be used to pave city roads as part of our nation’s road to recovery. It’s our goal to have surfers driving to the beach on roads paved with their old boards and to recycle the estimated 250 tons of neoprene waste that is created from wetsuit scraps each year!”
Green Foam Blanks
Since ReSurf has taken off, Santley and Cox set off on their next endeavor: to create a board made from recycled polyurethane foam and “put to rest a 50-year-old notion that toxic surfboard manufacturing waste and broken and used board components could not be recycled to create new boards,” through their new organization, Green Foam Blanks.
Matt “Mayhem” Biolos of …Lost Surfboards was given the opportunity to shape the first surfboard using a recycled blank, which is now on display at the Surfing Heritage Museum in San Clemente, Calif.
During an interview with Surfing Magazine, Santley said, “Well, the first board is 65 percent recycled foam. All I did was sweep up the foam dust from the shaping machine and bays of Mayhem’s factory and mixed it into our blending process. Of course, there has to be some virgin polyurethane in there to make everything adhere, but this is a huge start. We’re hoping to get the boards up to 70 to 80 percent recycled.”
“We’re just doing what we’re supposed to be doing,” he added.
The boards are already being praised as being equal in durability, lightness and function as current high-performance surfboards made with traditional, virgin polyurethane foam.
“Starting immediately, we will offer Green Foam Blanks to anyone who wishes to get a board made” said Biolos.

Interview on Channel 6 San Diego CW network

2009-01-30T08:48:00.001-08:00

http://www.sandiego6.com/mediacenter/local.aspx?videoId=566731@xetv.dayport.com&navCatId=2573

Green Foam Article In Wall Street Journals Marketwatch

2009-01-28T16:29:00.000-08:00

PRESS RELEASE
Green Foam Blanks and ReSurf Recycling Offer Surfboard Recycling and Waste Management Programs That Vow to 'Pave the Streets With Surfboards'
First-Ever High-Performance Recycled Polyurethane Surfboard Blanks Developed, Pilot Program Will Repurpose Previously Unusable Surfboard and Wetsuit Waste
Last update: 1:22 p.m. EST Jan. 28, 2009
SAN CLEMENTE, CA, Jan 28, 2009 (MARKET WIRE via COMTEX) -- Business partners and surf industry veterans, Joey Santley and Steve Cox, introduced two first-of-their-kind revolutionary endeavors, Green Foam Blanks and ReSurf Recycling, at the Action Sports Retailer (ASR) trade show in San Diego, Calif. on Jan. 22 - 24. Both organizations, which received high praise at ASR, are founded on the platform of creating a "greener" method of manufacturing surfboards, disposing of hazardous surfboard waste and ultimately leading to more environmentally sound urban communities through the repurposing of previously unusable and somewhat toxic waste.
With deep roots in the surf industry, both Santley and Cox recognized southern California as an epicenter for surfboard manufacturers with more than 1,000 surfboards being produced per day between Los Angeles and the Mexico border. Additionally, nearly 20% of the foam needed to shape each board is rendered as waste and inevitably ends up in landfills. This unusable foam, partnered with other somewhat toxic materials required to finish each surfboard, equaled an incalculable amount of waste coming from the surf industry. These facts, coupled with the belief that most surfers would be willing to do their part to help cleanse the industry due to their natural relationship with the ocean and nature, led to the launch of ReSurf Recycling in late 2007 as a philanthropic endeavor.
Founded with a mission to clean up the industry, ReSurf Recycling offers the first-ever cohesive plan to recycle all surfboards and the waste associated with their manufacturing, along with neoprene wetsuit scraps from the cutting room floor. Urging both surfers and board manufacturers to recycle old boards and manufacturing waste, ReSurf Recycling has developed a method that recycles somewhat hazardous surfing-associated materials into numerous products including asphalt for paving city roads. Additionally, the organization has invented a method of producing 100% recycled yoga mats made using neoprene scraps generated from wetsuit production and has recently finalized deals with wetsuit manufacturing giants, O'Neill and Quiksilver, to recycle all of its domestic unused materials. Most importantly, both recycling methods relieve waste haulers and landfill compliance management companies from the necessity of filling landfills with surfing's potentially hazardous products.
"As co-founder of Green Foam Blanks and ReSurf Recycling, I'm thrilled the nation has recently sworn in the first surfing president, Barack Obama," stated Santley. "We believe our efforts can directly contribute to the country's environmental agenda." Co-partner Steve Cox added, "ReSurf Recycling has literally invented a system of transforming discarded surfboards and previously unusable waste into asphalt and concrete that can be used to pave city roads as part of our nation's road to recovery. It's our goal to have surfers driving to the beach on roads paved with their old boards and to recycle the estimated 250 tons of neoprene waste that is created from wetsuit scraps each year!"
With surfer, community and environmental industry support for ReSurf Recycling even stronger than originally imagined in the first months of operation, Santley and Cox set out to take their surfboard recycling efforts to the next level and put to rest a 50-year-old notion that toxic surfboard manufacturing waste and broken and used board components could not be recycled to create new boards. Using a proprietary, patent-pending cryogenic methodology and working hand-in-hand with Sid Schneider and Scott Saunders from Oceanside, Calif.-based foam manufacturer Just Foam, Green Foam Blanks silenced the naysayers and created the world's first recycled surfboard blank. Matt "Mayhem" Biolos of ...Lost Surfboards was given the opportunity to shape the first surfboard using a recycled blank, which is now on display at the Surfing Heritage Museum in San Clemente, Calif. After being tested by both top surfers and shapers, Green Foam Blanks have been deemed equal in durability, lightness and function as current high-performance surfboards made with traditional polyurethane foam. Following the lead of Biolos, top surfboard manufacturers such as Channel Islands, Rusty, Doc, Timmy Patterson and Pat Rawson have all shaped recycled blanks from the company's first batch and proudly displayed their collective work for the entire industry to view at the Green Foam Blanks booth during ASR.
"When I first saw the recycled blanks, they reminded me of when recycled paper first came out; it was a bit rough, but got the job done all while saving resources and lessening waste. The same can be said for the recycled PU blanks," said Biolos. "The blanks are a tad coarse with some imperfections and take a bit of savvy to finish sanding them, yet for the most part the strength to weight ratio is on target. The specks of stringer and colored glue dust adds character and defines their look. Starting immediately, we will offer Green Foam Blanks to anyone who wishes to get a board made."
For more information on Green Foam Blanks visit http://www.greenfoamblanks.blogspot.com/ or http://www.resurf.org/ for more information of ReSurf Recycling.
Image Available: http://www2.marketwire.com/mw/frame_mw?attachid=912065 MEDIA CONTACT:
Bo Morris
SnL Communications
310-996-0239
Email Contact

Surf Shot Article 1/28/09

2009-01-28T14:16:00.000-08:00

Green Foam Blanks and ReSurf Recycling Offer Surfboard Recycling and Waste Management Programs
By: SurfShot Crew
Today 12:28pm
Overview
Photos/Videos

By SurfShot Crew
Green Foam Blanks and ReSurf Recycling Offer Surfboard Recycling and Waste Management Programs
First-Ever High-Performance Recycled Polyurethane Surfboard Blanks Developed,Pilot Program Will Repurpose Previously Unusable Surfboard and Wetsuit WasteSan Clemente, Calif. (Jan. 28, 2009) – Business partners and surf industry veterans, Joey Santley and Steve Cox introduced two first-of-their-kind revolutionary endeavors, Green Foam Blanks and ReSurf Recycling, at the Action Sports Retailer (ASR) trade show in San Diego, Calif. on Jan. 22 - 24. Both organizations, which received high praise at ASR, are founded on the platform of creating a “greener” method of manufacturing surfboards, disposing of hazardous surfboard waste and ultimately leading to more environmentally sound urban communities through the repurposing of previously unusable and somewhat toxic waste.With deep roots in the surf industry, both Santley and Cox recognized southern California as an epicenter for surfboard manufacturers with more than 1,000 surfboards being produced per day between Los Angeles and the Mexico border. Additionally, nearly 20% of the foam needed to shape each board is rendered as waste and inevitably ends up in landfills. This unusable foam, partnered with other somewhat toxic materials required to finish each surfboard, equaled an incalculable amount of waste coming from the surf industry. These facts, coupled with the belief that most surfers would be willing to do their part to help cleanse the industry due to their natural relationship with the ocean and nature, led to the launch of ReSurf Recycling in late 2007 as a philanthropic endeavor.Founded with a mission to clean up the industry, ReSurf Recycling offers the first-ever cohesive plan to recycle all surfboards and the waste associated with their manufacturing, along with neoprene wetsuit scraps from the cutting room floor. Urging both surfers and board manufacturers to recycle old boards and manufacturing waste, ReSurf Recycling has developed a method that recycles somewhat hazardous surfing-associated materials into numerous products including asphalt for paving city roads. Additionally, the organization has invented a method of producing 100% recycled yoga mats made using neoprene scraps generated from wetsuit production and has recently finalized deals with wetsuit manufacturing giants, O’Neill and Quiksilver to recycle all of its domestic unused materials. Most importantly, both recycling methods relieve waste haulers and landfill compliance management companies from the necessity of filling landfills with surfing’s potentially hazardous products.“As co-founder of Green Foam Blanks and ReSurf Recycling, I’m thrilled the nation has recently sworn in the first surfing president, Barack Obama,” stated Santley. “We believe our efforts can directly contribute to the country’s environmental agenda.” Co-partner Steve Cox added, “ReSurf Recycling has literally invented a system of transforming discarded surfboards and previously unusable waste into asphalt and concrete that can be used to pave city roads as part of our nation’s road to recovery. It’s our goal to havesurfers driving to the beach on roads paved with their old boards and to recycle the estimated 250 tons of neoprene waste that is created from wetsuit scraps each year!”With surfer, community and environmental industry support for ReSurf Recycling even stronger than originally imagined in the first months of operation, Santley and Cox set out to take their surfboard recycling efforts to the next level and put to rest a 50-year-old notion that toxic surfboard manufacturing waste and broken and used board components could not be recycled to create new boards. Using a proprietary, patent-pending cryogenic methodology and working hand-in-hand with Sid Schneider and Scott Saunders from Oceanside, Calif.-based foam manufacturer Just Foam, Green Foam Blanks silenced the naysayers and created the world’s first recycled surfboard blank. Matt “Mayhem” Biolos of ...Lost Surfboards was given the opportunity to shape the first surfboard using a recycled blank, which is now on display at the Surfing Heritage Museum in San Clemente, Calif. After being tested by both top surfers and shapers, Green Foam Blanks have been deemed equal in durability, lightness and function as current high-performance surfboards made with traditional polyurethane foam. Following the lead of Biolos, top surfboard manufacturers such as Channel Islands, Rusty, Doc, Timmy Patterson and Pat Rawson have all shaped recycled blanks from the company’s first batch and proudly displayed their collective work for the entire industry to view at the Green Foam Blanks booth during ASR.“When I first saw the recycled blanks, they reminded me of when recycled paper first came out, it was a bit rough, but got the job done all while saving resources and lessening waste. The same can be said for the recycled PU blanks,” said Biolos. “The blanks are a tad coarse with some imperfections and take a bit of savvy to finish sanding them, yet for the most part the strength to weight ratio is on target. The specks of stringer and colored glue dust adds character and defines their look. Starting immediately, we will offer Green Foam Blanks to anyone who wishes to get a board made.”For more information on Green Foam Blanks visit www.GreenFoamBlanks.blogspot.com or www.ReSurf.org for more information of ReSurf Recycling.About Green Foam BlanksUsing a proprietary, patent-pending cryogenic methodology, Green Foam Surf Blanks successfully created the world’s first-ever recycled polyurethane foam surfboard blank in November 2008, a feat widely considered impossible throughout the surf industry. Producing eco-friendly foam blanks that are as durable and high performance as all modern day shapes and materials, Green Foam Blanks has already provided blanks to some of the industry’s top surfboard manufactures, including Matt Biolos, Channel Islands, Rusty, Doc, Timmy Patterson and Pat Rawson. Green Foam Blanks are manufactured at Just Foam in Oceanside, Calif.About ReSurf RecyclingEstablished in 2007 as a philanthropic endeavor with a mission to clean up the industry, ReSurf Recycling is a first-of-its-kind systematic solution to clean surf industry waste. ReSurf Recycling offers both surfers and shapers convenient methods to recycle their old boards, wetsuits and manufacturing waste. Highlighting its unique recycling methods, ReSurf Recycling invented a unique process of recycling used surfboards into asphalt suitable for paving city roads, as well as recycling neoprene from used wet suits into yoga mats. ReSurf is endorsed by leading surf and environmental organizations, including SIMA, the Surfrider Foundation and Montec, inc (civil engineering).About Just FoamFounded in Oceanside, Calif. by Scott Saunders in 2004, Just Foam manufactures top quality polyurethane surfboard blanks. Beyond supplying top surfboard shapers with durable foam blanks, Just Foam was originally created as a vehicle to support community rehabilitation centers by employing individuals from these organizations and training them with a goal to move them into mainstream employment within the community. Just Foam teamed up with Green Foam Blanks in 2008 to help produce the first-ever recycled polyurethane surf blank and is the exclusive manufacturer for all Green Foam Blanks. Just Foam’s supplies have been approved by the local Fire Authority and are authorized for use in the manufacturing industry by the state of California. Just Foam does not manufacture any chemicals onsite.

Fuel TV Blog

2009-01-26T15:15:00.000-08:00

FUEL TV NEWS: Resurf Surfboard, Project Skateistan
Wed Jan 07 09:59:55 -0800 2009
The Resurf Surfboard Lives
Joey Santley and Steve Cox have done what many thought could not be done: they have produced a surfboard made of mostly recycled materials. Joey spoke with Surfing Magazine about the entire Resurf.org process.
"Well, the first board is 65% recycled foam. All I did was sweep up the foam dust from the shaping machine and bays of Mayhem’s factory and mixed it into our blending process. Of course, there has to be some virgin polyurethane in there to make everything adhere, but this is a huge start. We’re hoping to get the boards up to 70-80% recycled."
According to the story, Joey and Steve will be at ASR with their boards in booth #1036.
[Link: Surfing Magazine]

The Urethane Blog

2009-01-26T15:10:00.000-08:00

January 08, 2009
The Recycled Urethane Surfboard
The dark and dirty world of surfboards has finally

http://urethaneblog.typepad.com/my_weblog/technology/

2009-01-26T15:05:00.001-08:00

...LOST SURFBOARDS GOES GREEN
As reported on SURFINGTHEMAG.COM.
(First off we are not so full of ourselves to think we really went green. We made a teeny tiny little step...)
...Lost Helps Produce The World's First Recycled Surfboard. Check out the video of Biolos below.
The dark and dirty world of surfboards has finally taken one tiny, green footstep in the right direction By Andrew Lewis
We first met Joey Santley and his business partner Steve Cox back in the summer, when we were working on the Green Issue. We had heard from Matt Biolos that there was a guy fishing around his dumpsters at the end of each day, grabbing all of the waste from his shaping bays. Turns out the guy was Joey and he was very much a man on a mission. He was launching Resurf.org, a project committed to collecting all the broken surfboards and shaping waste clogging up our landfills and reusing it as filler in byproducts like asphalt and concrete. But as Resurf.org took off, Joey and Steve were already on to other things…like, you know, proving the foam blowing industry wrong and making the world’s first recycled surfboard. And the very first one — the one you see above — is a pretty damn perfect stick. Needless to say, Joey and Steve are on to something…again.
When did you first come up with the idea for a recycled surfboard?
My partner Steve Cox and I started brainstorming the idea as we were working on the Resurf.org project back in the fall. My dad had a foam blowing business when I was a kid, so I’m familiar with the process. I knew it could work.
Who did you go to first with the idea?
I went to Matt Biolos first and foremost because he and I have been friends since we were kids. But he was also the first to jump on board with Resurf.org and he’s always interested in helping us out. When I came to him with this recycled surfboard idea though, he didn’t believe we could do it. But he was up for the challenge. Sure enough, the first one — the one in the photo — came out great.
Explain the process of making a recycled blank without giving away all the secrets, of course.
Well, the first board is 65% recycled foam. All I did was sweep up the foam dust from the shaping machine and bays of Mayhem’s factory and mixed it into our blending process. Of course, there has to be some virgin polyurethane in there to make everything adhere, but this is a huge start. We’re hoping to get the boards up to 70-80% recycled.
What’s the difference between a regular polyurethane blank and your recycled blank?
Nothing, really. I mean, the blank has flecks of ground up stringer material in it, but as far as densities and weight, they’re coming out the same and we can alter all of that just like you can when blowing regular blanks. Some guys actually like the pieces of material mixed into the finished product — it looks really unique.
Who have you gone to with these recycled blanks and how has the response been?
I expected way more pushback then I got. All of the shapers are stoked to be working with recycled blanks. I’ve left a bunch at Channel Islands and they’re saving one for Kelly to work on, since he’s really into shaping his boards right now. Rusty has some, as well as Patagonia, Doc, Timmy Patterson, Pat Rawson and others. There are more guys, I’m just working to get them made and out the door.
Where are you making these blanks?
We just teamed up with Just Foam. We went to a lot of blank manufacturers and they all basically slammed the door in our faces. But Just Foam is into it, and they will be making these recycled blanks.
You will be able to see Joey and Steve’s recycled surfboards at the ASR Trade Show in San Diego, coming up on January 22 through the 24, along with information on Resurf.org. They’ll be at Booth #1036

Green Foam Featured on www.Greenlaunches.com

2009-01-26T15:02:00.000-08:00

January 15, 2009 - 4:55 AM Related Entries - Recycle Comments (0)
-->
World's first recycled surfboard for green surfing on blue waters
And since we have embarked on eco-friendly surfing (on waters and not internet) with the solar panels wetsuits, let me bring your notice to the world's first recycled surfboard. Joey Santley has partnered with Steve Cox to give shape to the first board that comprises of 65% recycled foam. All they did was sweep up the foam dust from the shaping machine and bays of Mayhem's factory and mixed it along with some virgin polyurethane to give birth to the recycled surfboard. Teaming up with Just Foam, the duo intend to raise the recycled content to 80%. The only visual difference that a user can note is this recycled board blank has flecks of ground up stringer material in it. But doesn't that speckled look make it more unique?
More...

Green Foam Blanks Launches at the ASR trade Expo

2009-01-23T08:46:00.000-08:00

Green Foam finds a way to reduce, reuse and recycle board blanks January 23, 2009 07:53 AM
The Green Foam team, including Joey Santley at far right, with their prototypes on the ASR floor. By ANDREW HORAN
Joey Santley kicked off this edition of ASR - and a new business - at 6:30 Thursday morning with a TV interview.
The San Diego local media love to drop in on the show, and Santley and his partner, Steve Cox, may be onto something special with their new company, called Green Foam.
They've found a way to recycle the industrial waste produced by board shapers and reuse it to create new blanks.
They've gone from a concept in November to prototype boards on display in their out-of-the-way booth on the ASR floor to being in current production. Santley reported commitments from 25 to 30 retailers on Thursday.
Just as important, he has shapers Matt Biolos, Timmy Patterson and Pat Rawson and others on board to use the blanks.
Here's how it works: Green Foam collects the foam scraps and waste from shapers, and ships it to Scott Saunders's Just Foam shop in San Clemente, where it uses a formula developed by Santley and Cox to press the scraps into new blanks. The result, according to testimonials from the shapers, is blanks with as much weight and strength as other blanks.
Santley grew up in his father's surf glass business, making boards and catamarans. Santley said that at one point, his father's company was producing 150 boards a day in the mid-1980s in a shop in San Juan Capistrano.
"I grew up blowing foam in the building next door. As a kid, I saw how to do everything," Santley said.
When his young son was diagnosed with autism three years ago, Santley went on a mission to improve the environment, which he thinks contributes to his son's condition.
"This industry is pretty toxic. It's our dirty little secret," he said.
Green Foam's catalog includes a full range of blanks, from a 5'9" grom model with squared-off tips to a 10'10" standup paddle board - 31 blanks in all.
Next up, he's working on a pilot project to collect other shape shop waste that can't be reused for blanks and instead mixing it into asphalt for road paving and repair. And he has a pilot project to reuse neoprene scraps in the body pads of wetsuits, yoga pads and cooler linings.

Hollywood wants GreenFoam

2009-01-13T08:58:00.001-08:00

Cameron Diaz's Green Foam

Perry Ferrell's GreenFoam

Mathew Mc Coughnahay's Green Foam

Green Foam is In Demand

2009-01-13T08:50:00.000-08:00

First Recycled Green Foam Blank TaaaDahhhhh

2009-01-09T17:12:00.000-08:00

Joey and Steve

2009-01-09T17:07:00.001-08:00

Cole cutting into some Green

2009-01-09T17:05:00.001-08:00

Timmy Patterson Shapes Green Foam

2009-01-09T17:03:00.000-08:00

Surfing The Mag /The World's First Recycled Surfboard

2009-01-09T15:17:00.000-08:00

The World's First Recycled Surfboard

The dark and dirty world of surfboards has finally taken one tiny, green footstep in the right direction By Andrew Lewis
Video interview with Joey Santley & Matt Biolos below!

We first met Joey Santley and his business partner Steve Cox back in the summer, when we were working on the Green Issue. We had heard from Matt Biolos that there was a guy fishing around his dumpsters at the end of each day, grabbing all of the waste from his shaping bays. Turns out the guy was Joey and he was very much a man on a mission. He was launching Resurf.org, a project committed to collecting all the broken surfboards and shaping waste clogging up our landfills and reusing it as filler in byproducts like asphalt and concrete. But as Resurf.org took off, Joey and Steve were already on to other things…like, you know, proving the foam blowing industry wrong and making the world’s first recycled surfboard. And the very first one — the one you see above — is a pretty damn perfect stick. Needless to say, Joey and Steve are on to something…again.

When did you first come up with the idea for a recycled surfboard?
- advertisement -

My partner Steve Cox and I started brainstorming the idea as we were working on the Resurf.org project back in the fall. My dad had a foam blowing business when I was a kid, so I’m familiar with the process. I knew it could work.
Who did you go to first with the idea?
I went to Matt Biolos first and foremost because he and I have been friends since we were kids. But he was also the first to jump on board with Resurf.org and he’s always interested in helping us out. When I came to him with this recycled surfboard idea though, he didn’t believe we could do it. But he was up for the challenge. Sure enough, the first one — the one in the photo — came out great.

Explain the process of making a recycled blank without giving away all the secrets, of course.

Well, the first board is 65% recycled foam. All I did was sweep up the foam dust from the shaping machine and bays of Mayhem’s factory and mixed it into our blending process. Of course, there has to be some virgin polyurethane in there to make everything adhere, but this is a huge start. We’re hoping to get the boards up to 70-80% recycled.
What’s the difference between a regular polyurethane blank and your recycled blank?
Nothing, really. I mean, the blank has flecks of ground up stringer material in it, but as far as densities and weight, they’re coming out the same and we can alter all of that just like you can when blowing regular blanks. Some guys actually like the pieces of material mixed into the finished product — it looks really unique.

Who have you gone to with these recycled blanks and how has the response been?

I expected way more pushback then I got. All of the shapers are stoked to be working with recycled blanks. I’ve left a bunch at Channel Islands and they’re saving one for Kelly to work on, since he’s really into shaping his boards right now. Rusty has some, as well as Patagonia, Doc, Timmy Patterson, Pat Rawson and others. There are more guys, I’m just working to get them made and out the door.

Where are you making these blanks?

We just teamed up with Just Foam. We went to a lot of blank manufacturers and they all basically slammed the door in our faces. But Just Foam is into it, and they will be making these recycled blanks.

You will be able to see Joey and Steve’s recycled surfboards at the ASR Trade Show in San Diego, coming up on January 22 through the 24, along with information on Resurf.org. They’ll be at Booth #1036

First Two (PU) Foam Blanks

2008-12-18T08:57:00.001-08:00

Here is a picture of the first 2 Green Foam Blanks made of Recycled Polyurethane.

1st Green Foam Surf Board in the Surf Heritage Museum

2008-12-16T07:52:00.000-08:00

On Dec 10th, 2008 the 1st ever Green Foam Surfboard shaped by Mayhem's Matt Biolis for Mason Ho was on display at the Surf HEritage Museum in San Clemente,CA.