Synthetic Turf Manufacturing
Turf manufacturing is seen by many as a clean recycling process that will help better the future. The popularity of synthetic surfaces is on the rise for public parks, schools landscaping and in professional sports arenas. This means that the manufacturing of artificial grass is also increasing to meet the demand.
Our synthetic grass is manufactured in a state-of-the art plant located in Georgia. We ensure the turf's quality is manufactured at the highest level. Our plant features the latest in tufting and coating technologies, guided by experienced technicians to ensure our product is consistent and meets the industry's highest standards.
The process for making synthetic turf can be related to process that makes products such as polyester and nylon. The chemicals used to make the artificial grass blades are melted and fed through a spinneret head (similar to a large showerhead) where it then forms a long fiber. The fiber then solidifies by some cooling process. Variations and additives used during the manufacturing process of fibers can alter the characteristics and end uses of the fibers tremendously. While usually being manufactured with a smooth texture and medium luster it can be changed to meet the needs of the consumer. Blue Sky Turf products are tailored to the specific weight or density to which the customer requires. The same is with the color whatever color is needed can be produced.
The manufacturing process of turf is done by technicians that will use many different machines and process to get the final product. The artificial grass in the turf is made from a process used in manufacturing called extrusion. the extrusion process uses a one-piece die where a material is forced through a hole that has a specific shape. The shape it goes through is the shape the strand will be. Different shapes of extrusion on the turf grass can have different effects which includes, the surface area, traction and the tensile strength. The compounding is the mixing of polymer, pigments, UV and process stabilizers, and several additives. This step is important in the fact these mixtures control the color, texture, consistency, and durability. These are predetermined based on the future use and mixed to meet the criteria of the needs. Our technicians pay close attention because one measurement off can ruin the whole batch.
Next on to the extrusion this process involves heating the material under pressure and mixing. This process continually stretches the material to give it its strength. The sheet will then be jerked or cut in partially for extra stability in the final product. These are held together by the base structure .After these steps are completed the material is ready for tufting or knitting; to be made in huge rolls which will weigh about 6 kg each to be later installed. The tape will be twisted in a regular number of twists per meter for better run ability during tufting / knitting. While all this is going on there are constant quality checks to make sure the turf will be up to par.