Road Tour Detour: Riddell Pt 2.,The Team USA Helmet

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Matt and I made our way to Elyria, Ohio just outside of Cleveland to visit with George Maczuga of Riddell. Riddell is the official football helmet and protective equipment partner for USA Football and the 2009 Junior National Team.

Maczuga was enthusiastic about Riddell’s new partnership with USA Football. “It’s perfect fit for us.” Citing USA Football’s commitment to youth football development, he lauded the partnership as an opportunity to help protect football players at the grassroots level.

As for Team USA and the Junior World Championship, “It’s going to be pretty exciting. It’s a once in a lifetime opportunity,” Maczuga said. He echoed the sentiment that kids will have four years to play for their college team, but only a short time to represent the United States.

Riddell’s predecessor, All-American Sports, founded in 1945, focused on reconditioning sports equipment. Riddell acquired the Elyria-based All-American Sports in 1994. In 2000, the company moved to its current facility in Elyria. And, in 2005, Riddell expanded to bring its manufacturing plant to Elyria and closed its Chicago location. Primarily a reconditioning plant, they now are charged with new helmet production.

The $2.5 million expansion increased the facility to 150,000 square feet. More than 300 employees work at Riddell plant in Elyria. The company’s corporate headquarters is located in Chicago, but Elyria processes more than 120,000 orders a year. The Riddell plant is busy year-round with only seven weeks of down time from September through October; oddly enough during football season. Each year, more than three million Riddell football helmets are used at all levels of football. More than 80 percent of the helmets worn in the National Football League are Riddell helmets.

Matt and I were able to tour the facility to see the Team USA helmets come through the production line. Team USA will be wearing the new Revolution Speed helmets (pictured here, here, and here). The helmets are molded in nearby Independence, Ohio. When they reach the Elyria facility they are sanded, buffed, primed and painted with up to three coats of high quality finish. The helmets are cured for up to 18 hours in a heated drying room, as the paint hardens into a glossy finish. The Team USA helmets are flecked in a white metallic finish.

The helmets move along on racks from station to station. Once reinforced with a bumper and padding, a facemask is attached. There are dozens of facemasks to choose from depending on the style of helmet, or player preference. The helmets are tested for impact and safety. We were able to watch several helmets being tested. They are fitted onto a head-shaped sensor, raised and then dropped to mimic the force of impact a player might experience. Once the helmet is approved, safety labels, trademark, and date of production stickers are added.

The helmet moves on to Betty, who applies the team decals. Betty has been applying decals for more than eight years at Riddell. She took great pride in being able to apply the Team USA logo on these helmets. Lastly, a hard-cup chinstrap  is attached, before final inspection.

With our newly manufactured Team USA helmet, Matt decided it was time to get suited up. He was fitted with Riddell’s CPX shoulder pads, which Team USA will also be wearing, pulled on the Team USA jersey, and strapped up his chinstrap. As we get closer to the first practice for Team USA and the IFAF Junior World Championship, the excitement continues to build. Riddell has already fitted most of the players for Team USA. And, the players are looking forward to putting on that jersey, pads and helmet and represent the USA.

We’re off to Pittsburgh for some fun in the Steel City.

– Mick