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Synthetic turf Made in Germany
The ABC of synthetic turf manufacture
The advantages are clear: Synthetic turf pitches ensure an interrupted playing and training timetable, outdoors, independent of weather and yet with consistently optimal playing conditions. In addition, this turf is extremely hardwearing and is characterised by a very long working life. No wonder that an increasing number of clubs are ordering Polytan|STI turf. But how exactly is synthetic turf made?
The manufacture of synthetic turf is comprised of four work stages: Extrusion, refining, tufting and finally, coating and final examination.
Extrusion – Everything starts small:
At the start of the manufacturing process are the small, white granules of polyethylene which are treated in a special process to create fine yarn threads, so-called mono filaments. This monofilament turf fibre later provides the turf with the natural-grass feeling. Use of high-quality raw materials, correlation of the chemical formulation with the final application, and continual monitoring of the manufacturing process are the factors for success of Polytan|STI.
Refining – From thin to thick:
In order to make the synthetic turf tough and durable, the single monofilaments are woven in a second step to thicker threads. Depending on the size required, four to six monofilaments are woven together to form either smooth or crimped yarn.
After refining the smooth yarn is similar to natural grass and is therefore preferred for use in the field of professional sport. A turf with smooth fibres is especially durable, easy to maintain and has a very long working life. Even under intensive use, the turf remains soft and pliable.
The crimped or texturized threads are even more hardwearing and are used therefore, mainly for amateur sport. The texturing process used for Polytan|STI means that the fibres maintain their appearance permanently, even under the most extreme conditions of use.
At this stage in the manufacture of the synthetic turf, the previously manufactured yarn is woven to form the grass carpet. The yarn is led via single spools to the tufting machine where it runs through the feeding roller to the needle where it is tufted into a ready-made substrate backing material before being pulled from below and cut to give the “grass stalk” the correct length. The end product of the tufting process is a grass carpet, also called Velours.
Coating and final examination:
After the yarn has been sown into the backing material the grass carpet is rolled together. The large rolls are transported by fork-lift truck to the fourth and final manufacturing stage of coating and final examination. When the synthetic turf is determined to be in perfect condition, it is packaged and delivered.
In the company’s own technical centre all products are thoroughly tested. In a simulation test for mechanical wear the turf is exposed to 100,000 test cycles using a Lisport Tester – this corresponds to around 20 years of use! With Polytan|STI customers are provided with quality from one source “Made in Germany”. From stalk to the finished installed stadium or club turf, everything is produced in our own manufacturing facilities.