PolyCoat Coating: Less is more

The back coating of the synthetic turf is meant to ensure the stability and fixing of the tufts over the useful life of the turf. Until now, the coating was usually made of latex. Polytan is taking it one step further. With the new polyurethane coating PolyCoat, the backing of the turf carpet has been improved in terms of functionality, environmental balance and use

The demands placed on modern synthetic turf systems are constantly increasing. Previous developments focused on creating a feel as close as possible to natural turfs, and on achieving high levels of availability and useability. These are joined today by additional aspects that include health, the environment, and later recyclability once the turf reaches the end of its lifespan. With our new PolyCoat backing coating, we’ve taken a fresh step in the direction of system compatibility and durability. Our new TuftGuard function has increased the pull-out-resistance of our tufts to over 50 newtons, ensuring that the tufts are optimally anchored in the turf backing from the very beginning. Each individual filament is separately secured once again through intensive penetration of the wear coat material into the tuft base. This helps prevent a domino effect in the event of a filament coming loose. Another positive effect is that the durability  limit of the complete system is reached significantly later in the system’s lifetime. This is especially evident in the stress areas such as the goal area or around the centre circle.

Resistance against moisture (hydrolysis resistance) has also been improved. The molecular structures of the PolyCoat coating stay unchanged longer, which also results in a longer service life. The improved processability ensures a more secure seam connection in all weather conditions. What’s more, Polytan has always used PU adhesive for its seam connections. Since this plastic is now used both as an adhesive and back layer, this results in an even better connection between the layer and the adhesive. This combination makes the whole system significantly more robust under all conditions than the latex coatings used previously.

Better functionality, longer service life, simpler recycling and less material used: Our new PolyCoat wear coat technology with TuftGuard function sets new standards for the backing coating of synthetic turf systems in a number of respects, and is representative of Polytan’s leading technological position.

The Polytan PolyCoat coating has another important benefit. The improved tuft insertion is achieved with a 30 per cent reduction in the amount of material used. Six tonnes of CO2 are thereby saved during production for a pitch measuring 6,000 square metres. Less material also means less weight, which in turn has a positive effect on transportation. The polyurethane (PU) of the back layer is compatible with the polyethylene turf fibres, which significantly simplifies recycling later. Separation of the materials is therefore no longer absolutely necessary. The turf and back layer can be recycled together.

Resistance against moisture (hydrolysis resistance) has also been improved. The molecular structures of the PolyCoat coating stay unchanged longer, which also results in a longer service life. The improved processability ensures a more secure seam connection in all weather conditions. What’s more, Polytan has always used PU adhesive for its seam connections. Since this plastic is now used both as an adhesive and back layer, this results in an even better connection between the layer and the adhesive. This combination makes the whole system significantly more robust under all conditions than the latex coatings used previously.

The Polytan PolyCoat coating has another important benefit. The improved tuft insertion is achieved with a 30 per cent reduction in the amount of material used. Six tonnes of CO2 are thereby saved during production for a pitch measuring 6,000 square metres. Less material also means less weight, which in turn has a positive effect on transportation. The polyurethane (PU) of the back layer is compatible with the polyethylene turf fibres, which significantly simplifies recycling later. Separation of the materials is therefore no longer absolutely necessary. The turf and back layer can be recycled together.

Better functionality, longer service life, simpler recycling and less material used: Our new PolyCoat wear coat technology with TuftGuard function sets new standards for the backing coating of synthetic turf systems in a number of respects, and is representative of Polytan’s leading technological position.