Do you know how artificial turf is made? If you’re curious about this, then you’ve come to the right place. Keep reading to learn about the process behind it.
The performance of any turf system often boils down to how good the raw materials used are.
The manufacturing process behind artificial turf isn’t actually as original or as extraordinary as the product is itself. In fact, the ‘grass’ part of any turf system gets made using tufting techniques that have been used in carpet-making for centuries, if not longer.
The initial step is blending together the proprietary ingredients in a hopper. Chemicals and dyes get added which give the artificial turf its traditional green color. They also help protect the material from ultraviolet rays.
Once the batch gets blended thoroughly, it is then fed into a big steel mixer. This batch will get automatically mixed up the point of having a thick consistency almost like taffy.
This thickened liquid will then get fed through an extruder. The exiting material comes out in long and thin strands.
These strands get placed onto a carding machine before being spun into loose ropes. These loose ropes then get pulled and straightened out before being woven into yarn. This nylon yarn will then get wound onto large spools.
The yarn is also heated. This is done to set up the twisted shape.
In the next step, this yarn gets taken to the tufting machine. Here, the yarn will be put onto a bar with skewers, or a reel, that’s behind the tufting machine. It’s then fed into a tub that leads to the tufting needle. The needle will pierce the primary backing of this turf, and it pushes the yarn directly into the loop. A flat hook or looper will seize and then release then nylon loop as the needle starts pulling back up. The backing gets shifted forward while the need pierces the backing again further down. This process will be carried about by hundreds of needles, and several hundred stitch rows can happen per minute. At this point, the nylon yarn will become a carpet of fake grass.
The artificial grass carpet gets rolled underneath a dispenser which spreads a latex coating across the underside. Simultaneously, a robust secondary backing also gets coated with latex. Both of these get rolled on a marriage roller, and that’s what puts them into a cohesive sandwich before sealing them together.
Following this, artificial turf gets put under heat lamps. This is done so the latex can be cured.
The turf then gets put through a machine which will clip off any particular tufts rising above the uniform surface. Next, the turf gets rolled into long lengths for packaging. The rolls then get shipped out to wholesalers.
The process of making artificial turf hasn’t changed too much over the years in terms of its general manufacturing. Having said that, tremendous advances have been made that result in higher safety and product quality than was ever imaginable a generation ago. Artificial Turf Source is a premium provider for all things related to artificial turf/grass.