Artificial Grass Manufacturing

Consideration for artificial grass' manufacturing process plays a significant role in understanding the nature and utility of synthetic turf.

The History Behind Artificial Grass Manufacturing

Artificial grass has undergone a number of manufacturing advances since its initial introduction. In the 1960s, artificial grass was introduced as 'astro turf', consisting of nylon fiber, filled-in carpets. Astro turf was created and developed specifically for playing fields. In the mid 1990s, the second generation of synthetic turf was developed .This turf consisted of polypropylene yarn which greatly improved its look, feel, and function. Infill material was then required to weigh down, secure, and stabilize the grass increasing its safety and durability. Third generation artificial grass, introduced in the late 1990s, utilizes polyethylene yarn improving its aesthetic appeal creating more natural colors and blade appearances. Modern artificial grass is considered third generation.

The Components of Artificial Grass

Artificial grass is essentially composed of blades, backing, and coating. Blades are composed of Polyethylene, Polypropylene, and Nylon. Qualities of these compositional elements include strength, abrasion resistance, oil and chemical damage resistance, resilience, softness, smoothness, and stain, soil, and sunlight resistance, along with a number of other beneficial features. The backing consists of three layers of fabric coated with a liquid material composed of polyurethane latex and polypropylene water permeable fabric. This coating holds the blade stitching together. Various combinations of these components create distinct turf that may be utilized for specific needs.

Manufacturing Techniques for Artificial Grass

Various manufacturing techniques further add to the lush aesthetic of artificial grass. Texturizing is a process where grass fibers are heat treated in order to create a crimpling effect. This procedure is used to produce natural looking under fibers or “thatch”. Knit-de-Knit is a process where grass fibers are knitted into socks, heat set, unraveled and wound onto bobbins. This procedure gives a curly appearance to the thatch.

Significant Characteristics of Artificial Grass

Specific fiber characteristics differentiate types of grasses. These same features determine the price of synthetic turf as well. An understanding of these attributes allows purchasers to recognize the most suitable product for their needs. These characteristics are as follows:

1. Face Weight
   Face weight, or denier, is the mass of fibers within the product. Greater face weight means more value.
2. Pile Height
   Pile height is the measure of fiber lengths. Longer blades mean greater cost. This feature adds to the face weight providing a lush appearance.
3. Gauge
   Gauge represents the distance between stitch rows. Closer rows represent greater value. This feature gives the artificial grass a natural look.
4. Stitch Rate
   Stitch rate represents the number of stitches per row. Greater stitch rate means greater value. More stitches convey a fuller look.
5. Color
   Various color combinations may be utilized to match the natural appearance of grass within certain regions. Solid, deep-green may be chosen for climates where grass typically stays green all year. Olive and natural green bi-color grass with a brown thatch may be chosen for areas with warm, drought-prone climates.

For specific questions concerning the manufacturing process of artificial grass, please contact EcoAlliance today.