Step 3 – Drying
Another part of the process in which the difference between superior and inferior quality artificial grass is highlighted, is the drying process of the coating.
Usually, artificial grass goes straight into the oven to dry. However, not with us. First, we put the grass into an infrared booth. In this booth the grass is given a ‘wallop’. We give the grass a good scare, so to say. This way the coating will already lose much of its moisture.
The advantage is that the oven can do its work on lower temperatures.
Is that important?
Yes. The more time you give anything to dry, the better, more beautiful and stronger the result. This applies to paint, your hair, a cake in the oven, glue… everything. This is also true for artificial grass.
And we understand: the higher the temperature in an oven, the more quickly the coating will dry, the faster you can have grass run around the spool and the more meters you can produce per hour. So from a financial point of view: go for it. But from the point of view of quality we say: not so much.
Step 4 – Perforating
Artificial grass needs to be perforated. If this is not done, rainwater cannot escape, and pools will form on your lawn.
It is a small step, but essential in the process.
Are there any differences in this? No. That being said, it is definitely an advantage that our backing consists of a double layer. This makes it more solid than most other backings. With every hole you make in the material, you lessen its integrity. But: the thicker the material, the less impact this has.
Step 5 – Rolling
Did you know that this might be the most underappreciated and probably the trickiest part of producing artificial grass? Rolling it up. Or dragging, as they say here in our factory.
The grass is 4 meters wide when it is dragged onto cardboard spools. The big challenge here is to make sure the tension that comes onto the grass is exactly – and we mean exactly – the same across the entire width of the spool.
Because what happens if the tension isn’t the same everywhere? The grass will ripple in places where there is less tension. It is given room to maneuver; to expand. This leads to unusable pieces.
Try to roll up a piece of carpet by hand. It will be tight in the middle, and somewhat loose on the edges. If you then unroll the carpet after a week, the edges will curl up.
And that is something we definitely do not want. We strive for uniform quality, across the entire width of the spool.
So here we are…
Indeed. The artificial grass is finished. It is wrapped in plastic wrap to protect it against external influences, and is then stored in the warehouse. Usually, it is then transported over the entire globe.