Artificial grass is based on a mixture of plastic granules and additives like UV stabilisers and colouring agents. This mixture is heated and pressed through an extruder head under pressure. This process results in the creation of individual synthetic fibers. The shape of the fibers is determined by the extruder head. Roughly speaking, there are two types of fibers: fibrillated and monofilament. The mix of synthetic materials used differs per product and supplier and ultimately determines the quality of the end product.
After the grass fibers have been made, the blades are reinforced. They are made resistant to strong tractive force and temperature fluctuations between -50 Cº and +50 Cº. The grass fibers are then coiled around large spools (bobbins) and shipped to the various artificial turf manufacturers. A major manufacturer of artificial grass fibers is TenCate in Almelo. The bobbins are then placed on a machine that is four metres in width, which uses needles to push the blades of grass through a backing.
The principle is similar to a sewing machine and the process is called tufting. The type of fiber, fiber height, distance between the needles, etc. determines the appearance of the turf and suitable usages. To secure the grass fibers in the backing, a liquid mixture is added, which is then hardened in an oven. This fixates the fibers. At this point, the grass roll has earned the name artificial turf and is ready for sale and installation.
ROYAL GRASS® PRODUCTION
Landscape Solutions bv manufactures Royal Grass®. The fibers used are produced exclusively by TenCate for Royal Grass®. Also see About Royal Grass® for more information. Royal Grass® offers various types of artificial grass designed specifically for private gardens, public landscaping and playgrounds. Royal Grass® is a patented and protected trademark. The process described above has been used since the introduction of artificial grass in the 1970s.
POWERED BY TENCATE IN THE NETHERLANDS
Landscape Solutions bv has worked together with TenCate to develop a completely new and innovative production process. The greatest advantage of this innovative process is that the artificial grass can be made recyclable. Products from this new production location are only available in limited quantities but, due to pending patent applications, the process used may not be published yet. These sustainable products can be recognised by the e-qual® certification label.