
How Is Artificial Turf Manufactured?
The manufacturing process of artificial turf involves several steps to create a synthetic surface that closely resembles natural grass in appearance, texture, and performance. Here’s an overview of how artificial turf is manufactured:
Material Selection
Yarn Production: The process begins with the production of synthetic yarn fibers, typically made from materials such as polyethylene (PE) or polypropylene (PP). These fibers are extruded through specialized machinery to create yarns of various lengths, thicknesses, and colors.
Backing Material: The backing material provides stability and support for the turf fibers. It is usually made from polypropylene or polyurethane and may contain additives for added strength, UV resistance, and drainage capabilities.
Tufting Process
Yarn Insertion: The tufting process involves feeding the synthetic yarn fibers through a tufting machine, which punctures them through the backing material at regular intervals. The spacing and density of the tufts determine the turf’s pile height, density, and overall appearance.
Backing Coating: Once the yarn fibers are tufted into the backing material, a secondary coating is applied to the underside of the turf to secure the fibers in place and enhance durability. This backing coating may consist of latex or polyurethane, which bonds the fibers to the backing and provides additional stability.
Trimming and Shaping
Trimming: After tufting, the artificial turf undergoes trimming to remove excess yarn fibers and create a uniform pile height across the surface. Precision trimming ensures a consistent and aesthetically pleasing appearance.
Shaping: Specialized equipment may be used to shape the turf fibers and create natural-looking contours, curves, and patterns that mimic the appearance of real grass.
Infill Application
Infill Material: Infill materials such as silica sand, rubber granules, or a combination of both are often added to the artificial turf to provide weight, stability, and resilience. Infill also helps support the turf fibers, improve shock absorption, and enhance playability for sports applications.
Infill Distribution: The infill material is evenly distributed across the turf surface using machinery or manual methods to ensure uniform coverage and proper integration with the turf fibers.
Quality Control and Testing
Quality Assurance: Throughout the manufacturing process, rigorous quality control measures are implemented to ensure that the artificial turf meets industry standards for durability, performance, and safety. Samples may be tested for factors such as fiber strength, UV resistance, colorfastness, and drainage efficiency.
Certifications: Artificial turf products may undergo testing and certification by independent laboratories or industry organizations to verify compliance with safety, environmental, and performance standards, such as ASTM International standards for synthetic turf.
Packaging and Distribution
Packaging: Once manufactured and inspected, the artificial turf rolls or panels are packaged and labeled for shipment to distributors, retailers, or installation contractors. Packaging materials may include protective wrapping, labels, and installation instructions.
Distribution: Artificial turf products are distributed to customers through various channels, including wholesalers, retailers, and direct sales. Installation contractors may purchase turf materials in bulk for use in landscaping, sports field construction, or other applications.
By following these manufacturing steps with precision and attention to detail, artificial turf manufacturers produce high-quality synthetic surfaces that offer durability, performance, and aesthetic appeal for a wide range of applications. Ongoing research and technological advancements continue to improve the quality, sustainability, and versatility of artificial turf products in the marketplace.
SGS Turf inventory of custom manufactured synthetic grass & artificial turf is some of the highest quality in the industry. Contact a rep today to explore your options.