The performance of artificial turf depends a lot on the quality of raw materials used in it. Almost every material that is used as carpet backing has been used as a backing material of synthetic turfs. These include: jute, plastic, polyester etc. However, a quality artificial grass set always uses polyester tire cords for backing.
Let us now come to the material used for making up the blades of synthetic grass; the most common ones are polypropylene and nylon. However, the manufacturing procedure may differ. The nylon grass blades can be created as slender sheets that get cut into strips or passed through moulds for producing fibres having over or round cross sections. The extruded creations are blades having almost similar feel and look of biological grasses.
The cushioning system of an artificial turf is made using polyester foam or rubber compounds. Sometimes the rubber tires are recycled and used while crafting the rubber base of synthetic grasses.
Now, as we have obtained some idea about the raw materials used for making synthetic turfs; let us get into their manufacturing procedure. The grass parts of these turfs are crafted using the similar tufting techniques as that of carpets. Here are the steps:
First, all the ingredients are put and blended in a hopper. For giving the artificial turf the conventional green colour, suitable dyes are added to the mixture. The mixture also carries some chemicals that can protect the grass from the effects of ultraviolet rays. When all these components are blended thoroughly, the mixture is transferred into a huge steel mixer. The batch gets mixed until achieving the desired thick consistency.
Next, the tick mixture is emptied into an extruder. The extruding will give birth to thin and long strands, which get placed on the carding machine for being spun into loose ropes. The loose ropes are tugged, straightened and finally get woven into yarns. Then, they are laid on a bar with skewers behind the tufting machine and transferred through the tube heading towards tufting needle. The tufting needle penetrates the turfs primary backing and drives the yarns inside the loop. A flat hook clutches and releases the nylon loop whilst the tufting needle tugs back. The backing gets shifted in forward direction and again gets pierced by the needle. The process takes place involving hundreds of needles and every minute witnesses stitching of hundreds of rows. Finally, the nylon yarn gets converted into an artificial turf.
Now, the artificial turf is rolled by a dispenser, which spreads a latex coating onto its base. Simultaneously, a sturdy secondary backing is also developed using latex. Both these are then sealed together. For healing the newly applied latex, the artificial turf is placed under the heat lamps. Then, it is passed through a machine that examines whether there is any uneven surface on the turf. Once, the manufacturing unit is sure that there is no flaw in their creation, the artificial turfs are rolled and packaged for being shipped to the wholesalers.
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