How Is AstroTurf Made?

Produce the blades of grass with nylon or polypropylene and blend in a hopper, an industrial machine that contains a conveyor and large part where mixing occurs. Add dye to the blades to give them the green color and mix with chemicals to protect each one from the sun.

Feed the nylon or polypropylene through a steel mixer until it is a taffy-like consistency. Insert the mixture into an extruder to create thin strands. This machine flattens the plastic into a long sheet. Place the strands on a carding machine so they undergo the process of separation. The machine will spin them into loose ropes, then pull, straighten and weave the ropes into yarn which turns into large spools.

Heat the yarn. This texturizes the product creating fibers or thatch. Insert the yarn into a tufting machine and place on the reel in the back. In this machine, the yarn is fed through and a needle pierces the backing. Another hook or looper grabs the yarn while the needle pulls back up and pierces the backing one more time. This process creates a carpet of artificial turf.

Roll out the turf and spread a liquid mixture of polyurethane latex and polypropylene water onto the bottom. This coating helps hold the stitching together. Use a marriage roller to attach a secondary backing made of three types of fabric coated with the same mixture of polyurethane latex and polypropylene water.

Place the turf under heat lamps to set the latex so it holds well. When done, clip off any excess turf and longer blades so there is a uniform look. Roll up and package.