Granules of polymers

To start with

Green Vision artificial grass production starts with the yarns. As a Middle East manufacturer with our own R&D, Green Vision knows the climatologic circumstances and implements this knowledge in its collection and choice of yarns. As you can see on the map, the Middle- East has one of the highest amounts of Kilolangley of the world. Kilolangley is a measure of UV exposure per square meter of surface area. This means that our artificial grass products must have the highest UV protection possible to obtain a long lasting resistance.

Our yarn is made from polymers, more exactly polypropylene or polyethylene depending on the future application of the grass. Specific substances are added to fulfill the highest requirements and obtain a long lasting resistance. Polypropylene and polyethylene are inert materials and don’t react easy with other substances.

The first step in the production of artificial grass yarn is heating the granules (polypropylene or polyethylene) until they become fluid. During this process, pigments for colors , UV resistance additives and other products are added.

Extrusion

Get in shape

The fluid mass is then extruded through a mould under high pressure. This mould imitates the structure of a natural blade of grass in 2 different ways: as monofilament tape or as a flat, fibrillated tape.

Monofilament: the fluid mass is extruded through a plate with small holes, to give it a certain strength and elasticity. The shape of the hole is determining the shape or cross section of the yarn. A mono filament yarn exist always out of more than one filament, for example 6, 8 or even 12 filaments.

Fibrillated tape yarn:; the fluid mass is extruded in a very thin film that is cut in small strips and fibrillated so that a honeycomb structure is formed.

Classic fibrillated tape products do tend to wear quicker than monofilament yarns. In monofilament yarns a lot of different shapes and cross sections are used: round, rectangle, s- shape, v- shape and all kind of other creative shapes.

For the design of a good monofilament yarn an optimal use of cross section design, material properties, experience and processing know-how is necessary. Research on base of polymer knowledge and mechanical calculations of our R&D department have resulted in several new shapes on the market, specially developed to provide the best durability and strength. These shapes are patent pending:

These shapes/cross sections may look maybe simple but in fact they are a result of mechanical engineering and experience width different polymers and polymer blends.

Twisting

To be twisted or to be wrapped

After the extrusion process the yarns are twisted or wrapped to provide a better performance in the tufting process, which is the next step.

Twisting: nothing more then turning the yarn around his own axe to become a more round yarn that can be processed easier.

Wrapping: a process where a very thin yarn is turned or wrapped around the multifilaments of a mono filament yarn.

Tufting process

Tufting

Now the yarn is finished, they can be tufted into a backing. A backing is a woven fabric/cloth that forms the back of the artificial grass carpets. Green Vision’s backings are made by Mattex Fabrics, also a member of our Mattex Group.

The artificial grass yarns or bundles of filaments are tufted into the backing in loops.

Tufting is a process where a needle (like a big sewing needle) is pushed through the backing together with the (grass) yarn to form a loop or a pile. The loops are cut to create individual (grass) piles. In a tufting machine you can have more than 1000 needles on a row depending on the width of the grass carpet (for example 4.0 m) and the intensity of the piles.

Application of latex on the back of the backing

Fix it

After the tufting process the (grass) piles need to be fixed to prevent them from falling out during usage..

In the third step, latex is applied to the backside of the backing to fix the piles and provide the backing more rigidity.

Latex is a product that is liquid (like yoghurt) when it is put on the carpet. During the coating process it hardens to give rigidity to the carpet and to fix the grass piles.

During the latex or coating process small holes are punched into the grass carpet for drainage. The holes are not visible but give the possibility, even during heavy rain, the water to flow off the carpet into the soil below.

Final inspection

Final inspection

The last step in the production of Green Vision is Quality Control. All carpets follow an online inspection to guarantee our quality standards.

Green Vision supplies more than 20 different sorts of artificial grass for a various series of applications, all with a different construction or performance.. These products are developed and tested in our fully dedicated and modern laboratory, in agreement with the environment. Green Vision only uses environmental friendly materials, free of heavy metals and other malicious material.

Standard grass rolls

Facts & figures

The last step in the production of Green Vision is Quality Control. All carpets follow an online inspection to guarantee our quality standards.

Green Vision supplies more than 20 different sorts of artificial grass for a various series of applications, all with a different construction or performance.. These products are developed and tested in our fully dedicated and modern laboratory, in agreement with the environment. Green Vision only uses environmental friendly materials, free of heavy metals and other malicious material.