Today’s modern JUTAgrass synthetic turf is the result of continuous investment in research and development focused on maximum durability, high load, improved surface softness , as closely as possible natural appearance and reduced maintenance.
Raw granulated (PP) polypropylene or polyethylene (PE) are the basic material for the manufacturing of artificial turfs. Fibrillated tape or monofilament is produced from this material which is called polyolefins. Fiber production takes place on the extrusion line, where the liquid mixture is continuously filtered using a dosing pump and then is extruded through the extrusion head. The extrusion head is either the shape of a flat slot and the result is a film which is then continuously cut longitudinally into individual strips – fibrillated tape, or extrusion head is circular with a number of profiled holes, resulting in a single fiber – monofilament. These fibers are tufted together to create yarns which make up the grass blades of the artificial turf.
For the production of fibrillated fibers thin films are extruded which contain parallel splits or ”points of fracture by design“. The final properties of the fibers are created by subsequent treatment such as stretching and heat which produces a curled structure. Up to 12 such fibers are combined to form the yarn of an individual carpet tufts.
Monofilament fibers are extruded as individual fibers. The extrusion process not only determines the thickness of the fibers, but allows for the design of a profiled cross section, such a lens-shaped profile.
One of the most important parameters for the manufactured yarn is its density. The parameter to measure yarn density is ”Dtex“ which specifies the number of grams per 10000 meters. A higher ”Dtex“ value means a more dense and robust fiber.
JUTAgrass® is manufactured using carpet-tufting technology. The fibrillated or monofilament fibers are stitched together using a tufting machine through a primary backing cloth according to the required parameters. The inserted tufts are fixed by a coating, termed the secondary backing, of Latex or polyurethane. A subsequent perforation process creates a grid of drainage holes through the backing. These drainage holes are typically 4 mm in diameter, typically spaced 8 to 15 cm apart. The perforated turf is then rolled onto hollow cores for transport and installation.
The field lines are created in 2 ways; either by tufting them in during construction using colored fibers, or by cutting the primary turf and gluing in sections of colored turf. Available colors for lines are red (terracotta), blue, yellow and white. The lines are manufactured from the same material as the playing surface.
Under one roof concept
JUTA has been manufacturing artificial turf in the highest quality since 2009. During its existence, JUTA has delivered more than 3,500,000 square meters of lawns of all categories. Competitive advantage and strongest feature is our unique approach to production which we refer to as “ Under one roof concept”. What does it mean? Put simply, all the components of the artificial turf are manufactured in house. From the primary backing and fibres, which are wrapped, twisted and doubled to produce yarns, which are then tufted and coated to make the final turf product. This concept gives us distinct advantages in terms of quality and cost control, flexibility in response to market demand, independency from external suppliers and short delivery times. It also allows us to acquire a unique knowledge of the whole process resulting in innovation and introducing new technology.