Synthetic Turf Manufacturing Process
Manufacturing synthetic turf consists of several key components. Several of the key components in the manufacturing process are listed below:
Pile Fiber Yarn - the synthetic grass is made of either the polyamide nylon/nylon 6.6 or polypropylene/polyethylene, which is then custom extruded into a monofilament ribbon form. The pile fiber has to allow for smooth ball roll and bounce, support non-directional foot traction, allow for water permeability, and have the correct balance of strength, elasticity and stiffness to withstand the wear and tear of regular usage.
Backing Fabric - the material to which yarn surface fiber are attached to form the underside of the artificial turf surface. The backing is typically fabricated from polyester tire yarns.
Tufting Process - Using flat-bed tufting machines like the one shown at the top of this page, the yarn fibers are knitted directly into the backing as it is being fabricated, to form a mechanically strong and stable structure. The knitting machines are between 4.5 m to 5 m wide, to minimize the number of seams required in an installation and offer greater surface uniformity in each installation.
The sewing threads are high-strength, weather resistant and pigmented to exactly match the color of the turf. For Athletic Fields permanent lines in many colors are knitted in during the manufacturing process to minimize installation costs and maintenance. These different colors are only knitted in straight lines going lengthways and not crossways. In most cases the backing is designed to permit water to flow through the fabric readily.
Foam and Urathane Backing - Foam provides cushioning for running or falling athletes in Athletic Field Applications. The foam is made of a closed-cell polymer alloy like polyurethane, typically 1/2" to 3/4" in height and perforated for vertical drainage. Urathane backing is used in many golf applications and athletic field applications. This process helps to prevent the yarn fibers from pulling out of the backing fabric.
Ultra-Violet Stabilization - all polymeric materials are subject to damage when exposed to the ultra-violet radiation present in sunlight. This problem gets more acute in areas with high humidity. Hence the yarn fiber have to be protected by the inclusion of appropriate organic stabilizers or UV inhibitors. Similarly, coloring pigments have to be selected for their ultra-violet resistant properties, for best retention of their original colors when exposed to sunlight.
Technical Criteria
Please refer to our Product Specifications pages.
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