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The life cycle of a ZORB ball

The life cycle of a ZORB ball is a lot more intricate and interesting than you may think. Every sphere is handmade with love in our factory located at the ZORB site in Rotorua, New Zealand. With over 25 years of experience, we are the worldwide experts in all aspects of product design, site design and ball manufacturing. Not only do we supply ZORB balls to our site in Rotorua, we also export them to various sites around the world.

The first step in the life cycle of a ZORB ball is obviously the manufacture

ZORB New Zealand | Woman assembling ZORB ball

We source the best materials available to ensure that we are producing a high-quality product that is suitable for use in a busy commercial environment. We use seven different types and grades of material to ensure our ZORB balls look great, are strong and safe and last as long as possible. Our ZORB New Zealand point of difference is that we use and test our own products and every year new features are tested and added on our site here in Rotorua, NZ.

It takes about 84 hours to construct a ZORB ball and once finished they weigh 90kgs. Once an order is received we get started with making the ZORB ball which includes measuring, marking and cutting the necessary materials. As well as the very important decision of what colour for the zip door and tunnel. Our ZORB balls feature a specially designed double zip door system which ensures riders are safely secured inside and the doors can be swapped out for a new one when necessary. The inner and outer ball are held together by hand dyed strings which are individually tied to anchors that are heat welded to the inner and outer ball.

The second step in the life cycle of a ZORB ball is use on site

ZORB Rotorua New Zealand | ZORB Operation Site

We keep our ZORB balls on site for about a year at ZORB Rotorua and bring out a fresh new fleet just before high season starts in December. Once we no longer have use for the ZORB balls they are carefully deconstructed and where possible parts such as the strings are able to be reused in the next ball.

The third and final step in the life cycle of a ZORB ball is recycling.

As a company we are very mindful of our carbon footprint and needing to discard 90kgs of plastics isn’t exactly environmentally friendly, and we try our best to divert as much waste from landfill as possible. That’s where the team at Matta Products in Otaki help us out. Once all recyclable parts are removed from the ball, the remaining parts are carefully cut up small and packed into bags. Matta Products then come through and pick up the plastic. Which then goes on to live another life as children’s playground matting.

Would you like to learn more or do you have questions? Contact us now!

November 21, 2022