Learn About Synthetic Grass Production Process
As we all know, artificial grass has become extremely popular in recent times and is being used widely instead of real grass. Artificial grass is used where it is difficult to grow grass or is too difficult to maintain a lawn. Most commonly used in stadiums and sports arenas however, nowadays, artificial grass is being used increasingly in playgrounds, homes, and other small-scale applications.
It was produced by using the same processes like carpets. However artificial grass has experienced numerous technological advancements over the decades. Artificial grass today is manufactured using higher quality materials and more realistic designs.
Materials that are used to create artificial grass
The most crucial aspect of artificial grass is the quality of the raw materials used, as they are the key element that determines the performance of the grass. Modern technology and advanced manufacturing techniques have resulted in the production of artificial grass that is very close to the “real” real thing. The grass is extremely robust and resistant to abrasion and wear, they are UV-resistant and protect the color of the grass from fading due to harsh weather conditions . Today, artificial grass is longer and lusher, and also more soft. Thegreenoma.com specializes in faux grass for dog run.
Artificial grass is typically made with three different materials:
Polypropylene
Polyethylene
Nylon
Grass Blades
The artificial grass blades are made from nylon or polyethylene. Polyethylene is the primary plastic that is popularly used to create bottles, plastic bags and other items. Polyethylene is usually offered in a solid form. It is then melted and mixed with other chemicals and colors to create a robust, UV-resistant and so on. Alternatively, the grass blades are made of thin nylon sheets which are extruded via molds to make fine fibers with an oval or circular cross-section. The blades made of extruded nylon from grass are of high-quality blades that appear and feel similar to real grass.
Thatch
The thatch layer is usually made from polypropylene. The thatch layer essentially gives added support and cushioning for the artificial lawn.
Turf Backing
Today, high-quality artificial lawns use polyester tie cord as their backing and the grass blades are fixed onto the turf backing by using a tufting machine which makes sure that grass blades and thatch are secured.
Cushioning
Most cushioning systems are made of rubber compounds or polyester foam. Sometimes, rubber tires are used to make the base, which is made of rubber. The base can also be made from recycled rubber or plastic. The top fabric panels and thread used for sewing the parts are made from high-quality materials that meet the same standards in regards to strength, durability and color retention.
Artificial Grass Manufacturing Process
The grass portion of artificial lawns is constructed by tufting techniques similar to that which is employed in the making of carpets.
Although this may seem a lot to our regular readers, it is worth noting to those who are interested. These are the steps involved in the manufacturing process.
First, all ingredients to make grass blades are placed in the bucket.
To this, the dyes which impart the “green grass” color and the chemicals that make grass UV resistant and protect it from the sun’s radiation are also added.
After the batch has been thoroughly blended, it is then fed into a mixer made of steel where it is blended into a thick liquid with an emulsion-like consistency.
This thick liquid is then processed by an extruder. long, thin strands are produced.
The thin strands are then put on a carding machine and spun to create loose rope. The ropes are pulled , and straightened. They are then woven into yarn that is wrapped around large spools.
Next, the yarn is heated until it is twisted into the form.
The yarn is taken back to the tufting machines and then placed on a rod with the reel in front of the tufting machines.
The yarn is passed through a tube to an edging needle. This needle is pierced through the turf backing, pushing the yarn into the backing in the form of a loop. The nylon loop is held and released by a flat hook or looper, while the needle moves forward and the backing is returned. This goes on until the backing is covered with rows of stitches. The carpet made of artificial grass is ready to be placed.
After the artificial grass carpet has been rolled, a latex coating is applied on the underside of the carpet. A secondary backing made of an even stronger material is coated with the latex and the grass carpet and the backing are then rolled into a roller that presses and seals two.
You can then cure the latex by heating it with lighting sources.
The grass carpet is taken through the machine, trimming any grass left.
The carpet is then cut into lengths of long lengths, and then shipped to packaging. After that, it’s directly delivered to the retailer.
Nowadays, the technology and production of artificial turf has come a long way. Artificial turfs constructed from high-quality chemically treated materials are impervious to UV, water and scratching. They can be utilized in a myriad of applications.