The Production Process of Non-Infill Artificial Grass: How Technology Ensures Quality, Durability, and Sustainability
The production of non-infill artificial grass is a highly technical and precision-driven process, combining advanced materials engineering with meticulous manufacturing. Every stage—from raw material selection to final inspection—directly determines the product’s elasticity, durability, safety, and environmental impact. As a leading global brand, Vivaturf has continuously refined its non-infill turf production through patented innovations, building a mature and efficient system that ensures superior performance across sports, recreational, and landscaping applications.
Core Manufacturing Stages of Non-Infill Grass
1. Raw Material Selection and Pre-Treatment: Controlling Quality at the Source
The fundamental materials for non-infill turf are grass yarn (PE/PP granules) and backing layers (non-woven fabric, mesh cloth, and adhesive).
Grass Yarn Preparation
Vivaturf uses 100% virgin PE (polyethylene) and PP (polypropylene) granules rather than recycled materials, which are prone to aging and contain impurities.
Granules are carefully pre-treated through:
High-Temperature Drying (80–100℃) to remove moisture.
Impurity Filtration using 100-mesh filters.
Precision Blending with UV stabilizers, anti-wear additives, and color masterbatch, accurate to 0.1%.
Vivaturf typically incorporates 0.8% hindered amine UV stabilizers, well above the industry average of 0.5%, providing outstanding anti-aging performance.
Backing Pre-Treatment
The backing combines non-woven fabric + fiberglass mesh.Non-woven fabric undergoes tensile testing (≥25N/5cm transverse, ≥30N/5cm longitudinal).
Fiberglass mesh receives epoxy coating to resist corrosion.
Vivaturf also performs air permeability tests to ensure ≥10L/m²·h, balancing waterproofing and breathability.
2. Grass Yarn Manufacturing: Defining Elasticity and Wear Resistance
Grass yarn is the functional core of non-infill turf. Vivaturf’s process involves:
Extrusion
Pre-treated granules are melted (180–220℃) in twin-screw extruders and extruded through precision molds designed for cross-sections such as U-shape or Y-shape.
Vivaturf uses gradient temperature control (zone differences ≤10℃) to prevent localized carbonization, ensuring yarn cross-section uniformity (≤0.05mm error).Cooling & Stretching
The extruded filaments pass through a water bath (20–30℃) for quick cooling and then are stretched at a constant speed (8–12m/min) to enhance tensile strength (≥18N, elongation ≥20%).Curling Process
Unlike traditional turf that relies on infill granules for resilience, non-infill turf depends on curled fibers.
Vivaturf applies a dual-roller thermal curling process, heating yarns to 80–100℃ and pressing them into a double-S curl (≥90% curl degree). This creates a self-supporting elastic structure that rebounds quickly under pressure, replacing rubber or sand infill.
3. Turf Weaving: Binding Grass Yarns to the Backing
The weaving stage transforms yarns into a stable turf roll using tufting technology.
Backing Alignment: Backing sheets are fixed on tufting machines with ≤1mm tolerance to prevent misaligned stitches.
Tufting Process: Needles insert yarns in a U-shaped loop into the backing. Vivaturf sets tuft gauge at 5–10mm, ensuring over 20,000 yarns per m². An intelligent tufting system monitors density in real time, eliminating inconsistencies.
Shearing & Grooming: Post-weaving, yarn tips are trimmed with ±0.1mm precision to ensure uniform height (30–40mm for sports, 20–30mm for leisure). Grooming aligns yarn direction for a neat finish.
4. Back-Coating: Enhancing Durability and Waterproofing
Back-coating secures yarns and strengthens the turf base.
Adhesive Application: Eco-friendly PU adhesive is evenly applied at 1.5–2mm thickness with ≤0.2mm tolerance. To improve adhesion, short-cut glass fibers (3–5mm) are mixed into the coating.
Curing Process: Turf passes through a controlled curing chamber (50–60℃, ≤50% humidity) for 8–12 hours. Vivaturf uses three-phase curing (initial–mid–final) to eliminate bubbles and ensure bond strength ≥30N/cm (industry average ~20N/cm).
Pressing: A roller press (5–8MPa) compacts layers, removing air pockets and preventing delamination during use.
5. Final Inspection and Cutting: Guaranteeing Product Reliability
Finished rolls undergo strict testing before shipment:
Physical Testing: Yarn pull-out resistance (≥30N), abrasion resistance (≤50mg/1000 cycles Taber test), UV aging retention (≥80% tensile strength).
Environmental Testing: Formaldehyde ≤0.1mg/m³, heavy metals ≤50mg/kg. Vivaturf also passes SGS and REACH certifications.
Visual Inspection: Checks for color difference (ΔE≤3), uniform density, and coating smoothness.
Cutting & Packaging: Rolls are cut to standard sizes (width 2–4m, length 25–50m), edges sealed with waterproof tape, and wrapped in PE protective film.
Vivaturf’s Patented Process Innovations
VRG Recycling Technology
Grass yarn and adhesive use thermoplastic materials with no non-degradable additives, enabling 100% recyclability.Zero-Glue Thermal Bonding
High-end models use heat fusion instead of adhesives, eliminating chemical pollution while improving bonding strength by 20%.AI Smart Quality Control
Sensors track temperature, speed, and density in real time, maintaining a 99.5% pass rate across production.
Why Manufacturing Defines Turf Quality
The production of non-infill artificial grass is a fusion of chemical engineering and precision mechanics, where every parameter must be tightly controlled. Vivaturf’s commitment to material purity, advanced yarn processing, superior coating, and sustainable innovation makes its non-infill grass stand out in elasticity, durability, and eco-friendliness.
For buyers and project owners, understanding the production process—such as yarn curl type, backing material, and tufting density—is key to evaluating product quality. With its refined manufacturing system, Vivaturf delivers non-infill turf that not only meets but often exceeds global standards.