Regular readers of our blog will know that we are very proud that our own artificial grass made in Britain. Our factory is a constant hive of activity producing grass carpet for both leisure and sports use. In fact we expect to produce half a million square metres of artificial grass this year alone. Enough we calculate to cover an area more than 50 times the size of Wembley!
Not only do we manufacture what we sell but our grass carpet is made in Britain – an extra source of pride for us. Located in Maryport, Cumbria our factory is traditionally British, with the majority of the staff being local people.
Our artificial grass factory is the oldest in Britain. Our grass products have been used in about every sphere of activity. From sports applications to people’s back gardens and children’s play areas. To display purposes in supermarkets, grocery stores and trade fairs/exhibitions. So we know the product inside out.
Manufacturing artificial grass involves several specially trained staff. All who have their own specific tasks in the production process. Manufacturing artificial grass splits into 3 key stages. The tufting operation (weaving of the grass carpet), the backing plant operation and the inspection process. Quality control checks play an important role in our manufacturing. We employ stringent and detailed checks throughout the process, using only top quality yarn, primary backing and latex.
The Tufting Operation
The collector board feeds the yarn through threading bars and yarn detectors down to the needles. There it is stitched into the primary backing. The tufted primary backing comes off the machine (having been checked by factory inspection staff). Then it goes through a lapping frame to be lap folded into lapping barrows. Lap folding is important as it helps preserve the quality of the tufting. Rolling the product up at this stage would risk pile distortion or damage to the backing stitches.
The Backing Plant Operation
The tufted primary backing is transported to the backing plant in rubber wheeled, lapping barrows where it undergoes ‘tip to tail sewing’. The latex coating is applied to the finished, tufted material. Then a special scraping blade (aka doctor blade) scrapes off the latex ensuring the correct weight per square metre. The product then goes into the ovens for curing and, once out of the ovens, is fed into the perforation unit. This is where the draining holes are punched into the material. Then the final product goes to the accumulator. This allows the grass carpet to be stored whilst re-rolling and further inspection is carried out.