How is artificial grass produced? Section 1

- Mar 23, 2018-

Here are huge differences on the quality of artificial grass. A simple example: most artificial grass types have single backing (which is the fabric on the bottom side) while Royal Grass products have double backing. This makes it firmer, easier to install, adds more back support to the grass and protects against shrinking and expanding.

Here we can summarize the production of artificial grass easily into five steps.

Step 1 – Tufting

Initially, there are two resources: fiber and backing. The fibers come on big spools, and the backing comes on rolls of over 4 meters wide. The first step is to bring those two together. This happens in the so called ‘tuft’.

The fibers are transported through tubes that are hanging on top of the machine into needles. Those needles stitch the fibers from above into the backing. A hook then pulls the thread back, creating a loop. This process is called tufting.

And indeed, that comes pretty close to sewing with a sewing machine. The difference is that the thread disappears in the fabric and the grass needs to stand up straight in the backing.

Step 2 – Coating

The fibers are now still loose in their backing. When you grab a fiber on the bottom side of the backing, you will pull it out without any effort. That’s why the bottom side will get a protective layer. This is a coating of glue, which makes sure that the fibers will stick to the backing.

There are two ways in which the coating can be applied: With most machines, the artificial grass enters the machine with the backing face up. The coating is then pulled over the backing.

We, however, choose to insert the artificial grass with the backing face down. The coating is then ‘licked’ to the bottom side. This process results in a more equal and smooth result.

Is the thickness of the coating important?

Yes. Absolutely. This is another difference between high and low quality artificial grass. The thinner the coating layer, the lower the cost price. But it is obvious that the fibers will be less solid in the backing, and will come out more easily when the grass is installed.

We don’t have to tell you why we chose a thicker coating. Right?