Sunny Grass Co.,Ltd Factory Tour

Ever wonder how simple plastic becomes your beautiful lawn? It all starts with white plastic pellets that act as the base material which are combined with green pellets that hold the colors, U.V. stabilizers and additives.

After undergoing multiple inspection points, including measuring the turf fiber length and minor trimming, the turf is moved to a device that simulates football cleats to affirm the turf’s durability.

It’s through this constant evolution, synthetic grass has become the high quality material we know today for most landscape installations.

The actual green blade of synthetic grass is comprised of a polyethylene material, a common form of plastic that can be found in items such as bottles and plastic bags. The polyethylene comes in a solid pellet form and is heated down along with any color tones and UV resistant additives.

The thatch layer of synthetic grass is made from a polypropylene, polyethylene or nylon material. The thatch layer provides the turf with an added layer of support and blade recovery.

Equipment melts the plastic together and extrudes it through a perforated steel plate. The strands exit the steel plate into a trough of water which solidifies the synthetic grass mixture. A machine pulls the strands through a large pulley and keeps them separated while they move on to the next station. Rollers stretch the strands until they become as thin as real grass. Spools hold the synthetic grass strands. Once a spool has been filled, different color strands are woven together to form multiple synthetic yarns. The yarn is prevented from slackening by traveling through guides while it is wound around a giant spool.

Mesh fabric merges with synthetic sheeting while the synthetic yarn travels through a tubing to a tufting machine. A tufting machine is like a giant sewing machine and contains over 200 needles to hook the yarn through the sheeting. This machine gives the grass blades and thatch a more secure hold which also increases the turf’s life and durability.

While the turf is being tufted, small knives underneath cut the ends to make the yarn appear like grass blades. The backing is moved to a coating roller which picks up adhesive to apply to the turf’s backing.

The adhesive is dried in both open air as well as an enclosed setting.

As the turf exits the drying, hot pins burn holes into the turf for drainage.

Sunny Grass Co., Ltd, specializing in the research and development, manufacturing and sales of artificial turf. Sunny Grass has more than 300 employees, a modern production base of 40,000 square meters, two drawing bases, a artificial turf production base, a wire mesh production base, and a rubber and plastics production base. There are more than ten professional construction teams in China, providing the overall system construction of sports grounds with artificial turf, rubber track, wire mesh, lighting system and shock pad. If there is any questions about artificial grass, feel free to contact us.