Manufacturing Process

When you’re selecting a sports surface you don’t want restrictions and you shouldn’t have to compromise. As the only UK manufacturer that can offer the full range of woven, tufted and needlepunch synthetic sports surfaces, we can provide you with the artificial surface which best suits your requirements.

Needlepunch Sports Surfaces

The construction starts with polypropylene staple fibres being placed into a machine at the exact pile weight requirement. They are combed into line through a carding machine layering the fibres in one direction: then into a needling loom which interlocks the coarser denier fibre creating a flat carpet.
This is then placed on a structure machine which designs the required pile design and height specification.

Woven Sports Surfaces

Woven carpet is manufactured in one process, interlacing two sets of threads namely the warp, at the same time the pile is trapped between the backing yarns with the weft, the yarn is then cut into either a U or a J shaped tuft.
Woven products give a high tuft density than a tufted carpet, the pile height though can only be manufactured to a maximum of 18mm, generally a woven carpet is sand dressed or no infill at all, and you can use polypropylene, polyethylene or nylon fibre for this application.

Tufted Sports Surfaces

Tufted carpets are created by needling the fibre into a pre formed primary backing cloth creating a loop which is cut into a U shape by a looper. A secondary backing in the form of latex is then applied, to increase porosity holes are punched into the carpet.

On longer pile tufted carpets a pre formed fleece backing is used which increases tuft retention. Tufted carpets offer sand dressed, sand and sand rubber filled surfaces. Polypropylene, polyethylene along with nylon can be used and you can achieve up to 70mm pile height.

Playrite also manufacture a range of artificial grass and turf which is suitable for use in the garden. Nearlygrass makes an excellent alternative to natural grass and a synthetic grass product can save money in the long run, as well as reduce maintenance costs.