Anaheim, CA (PressExposure) March 08, 2012 -- One of the most important elements in the process of engineering and manufacturing synthetic grass [http://www.syntheticgrasswarehouse.com/] is how yarn is extruded. The way in which the yarns are composed contribute to the texture, feel, and overall aesthetic of the synthetic turf. Thus, knowing the process of yarn extrusion really puts into perspective the detailed procedure of making realistic and beautiful artificial grass. With the new processes and technologies for artificial grass yarn extrusion, state of the art turf products are readily accessible available on the market today.
The polymers in which modern artificial grass products are comprised of assist to create supple and natural grass. A combination of nylon, polypropylene, and polyethylene are the important ingredients used to comprise the yarns in synthetic grass. These polymers come in the type of pellets and are placed into a hopper. Other ingredients such as dye, ultraviolet protective solutions, stabilizers, and other additives are then added in to the hopper as well. All of these ingredients are mixed thoroughly inside a big steel mixer, which melts the pellets down into a pliable consistency like that of taffy. Once at this point, the extrusion method is ready to start.
The yarn extrusion method starts with the thick consistency of polymers and additives getting fed into an extruder. The extruder looks a lot like an enlarged perforated steel plate. The liquid mixture filters via these holes, generating long, thin strands, which are the basic makeup of the turf blades. These long strands are then carried through a water trough to harden and solidify. The strands are then sent by means of the carding machine to keep each yarn separate and be stretched. The machine continues to pull the yarn strands to increase durability, whilst attaining the perfect blade thickness, most comparable to natural grass. Then, these yarns are rolled into spools. When the spools are complete, they're manually removed.
After, numerous spools at a time are unwound by machinery, and intricate yarns are woven. These yarns produce monofilament strands, characterized by larger fibers and a larger denier than multifilament yarn fibers. After the monofilament yarns are woven, they are re-spooled with all the help of guides to be able to preserve it from becoming slack. The yarns are then heated to set numerous shapes.
Once the yarn extrusion and weaving processes are done, the turf is able to be tufted. The woven yarn spools are placed through a tufting machine to sew and stitch the fibers to a synthetic major backing, a lot like a sewing machine with hundreds of needles. The looped yarns are then cut on the other side of the turf to replicate grass blades. After the primary backing and secondary backing are coated with latex and sandwiched together, the turf is cured with heat. Then the completed item goes by means of a machine to clip off any extra long yarns.
The method of creating and extruding yarns is an integral part of the complete synthetic grass production process. It really is within this process that modern artificial grass is able to genuinely replicate natural grass in both looks and texture. Modern yarn technology is the driving force behind creating beautiful and realistic artificial turf.