How is Artificial Turf Made?

One of the biggest factors that sets ProGreen apart from other companies is the fact that we are a true artificial turf manufacturer. We do not purchase our yarn from a third party, nor do we hire a third party to do our tufting and coating. The entire process, from start to finish, is done in our manufacturing plants. Care to know how artificial grass is made?

Just like with any production line, we start with the raw materials. Our fibers are made from the highest quality resin pellets, which are melted down to create artificial turf fibers. It is during this process in which we add our UV inhibitors and other additives that help ensure our turf products will last. Since these features are built-in to the turf, they do not fade or wash away over time. This process of melting the resins to create the yarn is called extrusion.

This is a picture of one of our extrusion machines and the extrusion process:

Artificial grass fibers being extruded from high quality resins in ProGreen's Dadeville, Alabama facility.
Turf Fiber Extrusion

Once the extrusion process if complete, we have big spools of yarn like these:

Turf fiber rolls in ProGreen's Dadeville, Alabama facility.
Turf Fiber Spools

Then, we take these big spools of yarn and send them to our tufting and coating plant. Tufting is the process in which these turf fibers are sewn into the backing, like this:

Turf fibers being tufted into backing at ProGreen's Chatsworth, Georgia facility.
Fibers Tufted into Backing

Once the turf is tufted, it is sent to the oven for coating. This is the part in which our patent-pending ProFlow technology is applied, resulting in the finished product:

American made turf rolls ready for shipping.
Turf Rolls Ready to Ship

It does seem like there are a lot of complicated steps in the manufacturing process, which is why you should be very picky about the artificial grass you choose for your project. As you can see, there are two main components to manufacturing synthetic turf: extrusion and tufting/coating.

Many companies will purchase their yarn from overseas and tuft it in their own facility or extrude the yarn themselves and hire a third party to do the tufting. In both of these situations, the turf “manufacturer” sacrifices control over the process, which also means they sacrifice quality assurance. If quality and American made products are of importance to you, be sure you do your homework and know exactly what you are getting. At ProGreen, we have complete control from start to finish, and we can proudly stand behind our products as we know every single thing that went into making them.