3 Dadeville Alabama Plant Extrusion / Yarn Manufacturing Most Comprehensive Product Portfolio in the Industry – PE / PP fibrillated, PE slit tape.

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Presentation transcript:

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Dadeville Alabama Plant Extrusion / Yarn Manufacturing Most Comprehensive Product Portfolio in the Industry – PE / PP fibrillated, PE slit tape mono, spinerette monofilament PE and nylon. New, State-of-the-Art Extrusion Technology Latest Generation of Electronics for Precise Computer Controlled Quality Twisting – Newest Generation With Dual Yarn / Dual Color Capabilities Texturizing – nylon and PE Latest Testing Equipment – QUV Accelerated Weatherometer, Instron, Color Camera 5

Extrusion Process Drawing Annealing Fibrillating Winding Twisting 6 Film Spinerette 6

Slit Film Slit Film Extruded into a film sheet Cut into tape Fibrillated or Mini Tape Twisted 7

Monofilament Top View of Spinerette Polymer Flowing Through Spinerette Spinerette Monofilament Extruded Through Spinerette holes to designed shape Twisted Top View of Spinerette Polymer Flowing Through Spinerette 8

Monofilament Competitors Duraspine Nexcel Mono Spinerette Monofilament Shape is critical to durability Competitors Duraspine Nexcel Mono 9

Definitions: Yarn Physical / Quality Properties: Denier – The weight in grams of 9,000 meters of fiber Cross Section – The width and thickness Tensile Strength – The force required to break the yarn in the axial direction Elongation – The amount the yarn will elongate prior to break measured in percentage Shrinkage – The amount a yarn will shrink when heated measured in percentage UV Rating – The percent loss in tensile strength and elongation after 8,000 hours of UV exposure

Only fully integrated turf manufacturer in North America Tufting – Multiple gauges / pile heights on new high speed tufters Coating – urethane coating , hot melt coating Uniform quality process – including our own Lisport Wear Machine 12

Chatsworth Plant Tufting 10 Tufting Machines 3 New High Speed Machines 3 Machines with dual feed systems and dual creels Wide Range of Gauges, including 3/16, ¼, 3/8, ½, ¾ Pile Heights from ¼ inch up to 3 inches 13

Tufting Tufting Primary Backing A single or multiple layers of woven or non-woven materials, into which the fiber is tufted Pile Height The height of the pile (fibers) above the primary backing Pile Weight The weight of the fibers per square yard of turf Tufting Gauge The distance between tufted rows Stitch Count The number of tufted stitches per 3 inches 14

We have made changes in our primary backing to allow more Dimensional stability. We added a reinforcement layer to prevent wrinkles. We increased the thickness of the two woven primary backings.

Chatsworth Plant Coating Urethane Coater dedicated to synthetic turf products only Over 100 million square feet of coating capacity Proprietary urethane formulation yielding best tuft binds in the industry In-house compounding provides maximum control over coating formulation and consistency from batch to batch. Perforation pattern of 3/16” hole on 2” x 2 1/8” centers provides the most consistent drainage in the industry. 17

Coating Coating Secondary Backing A coating layer applied to the primary backing after the fiber pile has been tufted, which serves to enhance tuft bind Polyurethane A polymer system that is formed by mixing two parts, monomer and a catalyst Coating Weight The amount of secondary coating per square yard of turf Perforations Holes through the primary and secondary backings to allow for drainage 18

Tuft Bind It is important to note that tuft bind test are done from the top not the bottom of the sample. PU penetration around the bundle of fiber (all filaments) is most important.

Tuft Bind The look of the coating on the back is less important than the amount of coating around the fiber bundle. Most commission PU coaters sell the coating by the ounce therefore the more you put on the back the more they can charge. To add weight you can add filler to the PU mix and the material will lay on the back of the turf not around the yarn bundle. They can also add air to the PU mix to make it look fuller.

Tuft Bind Note the area where the interior bundles or ends are not covered in PU coating.

Sprinturf has a comprehensive quality control process from resin through installed turf

Extrusion Quality Control Quality Control Testing for Extrusion and Twisting Raw Materials Resin – Melt Flow Master batch – Spectral Color Tape Lines and Monofilament Yarn denier – once per line per shift Spectral color – each line each doff Break load - once per line per shift Extension (% strain) - once per line per shift % Shrinkage - once per line per shift Curl testing – each doff Spin finish % - once per line per shift if applicable Twisting Curl testing- once per shift Twisting turns per inch – each twister each shift Spin finish % - on each lot Visual Inspections of twisted yarn (finished goods) Performance Testing QUV – 8,000 hours UV testing 3rd Party UV Testing

Tufting / Coating Quality Control Quality Control Testing for Tufting and Coating Tufting Quality Checks Audit Teams Pile Height – Each Roll 12 auditors Stitch Count – Each Roll Audit process every 2 hours Width / Length – Each Roll Daily report and monitoring Face Weight – Every Third Roll Performance Testing Coating Quality Checks Lisport Wear Testing Urethane Gel Time, Viscosity, Water – Each Batch Width – Three Times Per Roll Length – Each Roll Pile Height – Each Roll Perforations – Each Roll Coating Weight (side, center, side) – Every Third Roll Tuft Bind – Every Fifth Roll

The Benefits of True Integration All fiber extrusion, tufting and coating is performed IN-HOUSE Sole source accountability Customized solutions Quick turnaround times and simplified logistics Innovations across entire spectrum Industry leading economics 25

Total Vertical Integration (from resin pellet to installed turf) Newest Generation of Equipment (over $35 million of assets) Proprietary Designs and Material Formulations Yield High Quality Products that are 100% Made in America.