One of the main factors that make ARTurf apart from other artificial grass suppliers is the fact that we can control the whole process of manufacturing. Most types of yarns are made in our extruding plant, and we do not pay to a third party to do tufting and backing coating. The whole process, from start to finish, is done in our artificial grass factory. Want to know how our artificial grass is made?
Artificial grass yarns are almost the most important part of the artificial grass system. It will affect the performance and lifespan of the project.
Our yarn is made from the best quality resin pellets, which are melted down to create artificial grass yarns. It is during this process in which we add high quality UV inhibitors and other additives which help ensure our synthetic grass products will last. Because these features are built-in to the grass, they do not fade or wash away over time. This process of melting the resins to create the yarn is called extrusion.
When artificial grass yarns are finished, they can be tufted into a backing. The backing is a woven fabric/cloth that forms the back of the synthetic grass.
The artificial grass yarns or bundles of filaments are tufted into the backing in loops.
Tufting is a process where a needle (like a big sewing needle) is pushed through the backing together with the (grass) yarn to form a loop or a pile. The loops are cut to create individual (grass) piles. In a tufting machine, you can have more than 1000 needles on a row depending on the width of the grass carpet (for example 4.0 m) and the intensity of the piles.
Arturf artificial grass factory is equipped with the most advanced tufting production lines. More than half of our workers on the tufting production lines have 6+ years of working experience.
After the tufting process, artificial grass yarns need to be fixed to the backing, to prevent them from falling out during usage.
In the third step, latex or polyurethane is applied to the backside of the backing to fix the yarns and provide the backing more rigidity.
Latex/polyurethane is a product that is liquid (glue) when it is put on the carpet. During the coating process, it hardens to give rigidity to the carpet and to fix the grass piles.
During the coating process, small holes are punched into the grass carpet for drainage. The holes are not visible but give the possibility, even during heavy rain, the water to flow off the carpet into the soil below.
The last step in the production is the quality and specifications inspection. All artificial grass carpets follow an online inspection to guarantee our quality standards.
Our artificial grass factory supplies many artificial grass products for various series of applications. These products are developed and tested in our fully dedicated and modern laboratory, in agreement with the environment.
For each individual order, we have inspection procedures to ensure every step reaches the strict standard.
Before sending the finished products to customers, the artificial grass rolls are stored in our modern warehouse, which is specially designed for storing artificial grass rolls. Each roll has a code to differentiate different customers’ goods.