The following overview of how synthetic grass is manufactured is not specific to any one manufacturing process because each brand will include their own addtions to provide certain benefits and advantages. Instead of trying to cover long and short knap grasses, this “How To” guide simply explains the materials and the construction of synthetic grass carpet.

I just called the synthetic grass a carpet and that is relevant because the grass part of a synthetic turf system is made with the same tufting techniques used in the manufacture of carpets.

  1. All of the ingredients are blended together in a hopper. Dyes and chemicals are added to give the turf its traditional green color and to protect it from the ultraviolet rays emanating from the sun.
  2. After it has been completely blended, it is fed into a large steel mixer and it mixed until it has a thick, taffy-like consistency.
  3. The thickened liquid is then fed into an extruder from which it exits in a long, thin strand of material.
  4. The strands are placed on a carding machine and spun into a loose rope. The loose ropes are pulled, straightened, and woven into yarn. The nylon yarn is then wound onto large spools.
  5. The yarn is then heated to set the twisted shaped.
  6. The yarn moves on to a tufting machine. The yarn is put on a bar with skewers (a reel) behind the tufting machine. It is then fed through a tube leading to the tufting needle. The needle pierces the primary backing of the turf and pushes the yarn into the loop. A looper, or flat hook, seizes and release the loop of nylon while the needle pulls back up; the backing is shifted forward and the needle once more pierces the backing further on. This process is carried out by several hundred needles, and several hundred rows of stitches are carried out per minute. The nylon yarn is now a carpet of artificial turf.
  7. The artificial turf carpet is rolled under a dispenser that spreads a coating of latex onto the underside of the turf. At the same time, a strong secondary backing is also coated with latex. Both of these are then rolled onto a marriage roller, which forms them into a sandwich and seals them together.
  8. The artificial turf is placed under heat lamps to cure the latex.
  9. The turf is fed through a machine that clips off any tufts that rise above its uniform surface.
  10. Then the turf is rolled into large v/lengths and packaged. The rolls are then shipped to the wholesaler.