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