Case Study

Decathlon’s new beginner bodyboard is a sustainable, durable, and user-friendly product designed through eco-conscious innovation. It delivers better performance for beginners, supports the circular economy, and reduces the environmental impact of traditional board manufacturing.

Problem

Traditional beginner bodyboards often fall short in both performance and sustainability. Materials used in mass-produced boards tend to be non-recyclable, environmentally damaging, and not optimised for durability, leading to short lifespans and increased waste. Decathlon decided to improve the components and manufacturing process of their beginner board without compromising quality, safety, or usability.

Solution

Decathlon partnered with JSP and Petibol to develop a next-generation beginner bodyboard made from ARPRO 35 Ocean — a lightweight, high-performance expanded polypropylene (EPP) that contains 15% recycled maritime waste from old fishing nets and ropes. By redesigning the board for better ergonomics and using a circular manufacturing approach, the new bodyboard not only enhances performance but significantly reduces its environmental footprint.

Key Features & Benefits

Sustainable Material 

• Made from ARPRO 35 Ocean, which contains 15% recycled content sourced from maritime waste (e.g., old fishing nets and ropes).
• Results in a 7% reduction in CO₂ emissions during production.
• Fully recyclable, aligning with circular economy principles.

Improved Performance for Beginners

• Redesigned shorter, classic-inspired shape makes wave catching easier.
• Ergonomic handles ensure a more stable, secure grip.
• Suitable for a wide weight range (15–85 kg), making it ideal for family use.
• 39% stronger than its non-recycled predecessor, offering better stability and durability.

High-Performance Material Benefits

• Lightweight, resilient, and energy-absorbing material that withstands multiple impacts.
• Maintains buoyancy and waterproofness without losing form.
• Retains original shape even after heavy use due to high shape memory.

Circular Economy & Zero-Waste Manufacturing

• Manufactured by Petibol in Portugal with no glue and no waste.
• Customers can return used boards to Decathlon stores for recycling.
• Up to 8% of the recovered material is reused in new production runs.

We opted to make this bodyboard out of expanded polypropylene of which 15% comes from recycled fishing nets. This material has many advantages such as its resistance, lightweight form, buoyancy and waterproofness."

Product Engineer Bodyboard, Edel Leon