Manufacturing

How It's Made

 

Below is a summary of the manufacturing process

 

 Uniform polyethylene pellets are loaded into a hopper

 

A large extruder melts the pellets and extrudes the fibers


The polyethylene fibers are cooled and stretched over rollers


The fibers are wound together in a group of eight fibers

The wound fibers are packaged on a cone (spool) and shipped


The cones are loaded into creels and fed to the tufting machine

The fibers are tufted into the backing and inspected (greige)

Urethane is spread on the backing to lock in the stitches