Countryside’s Guide to Poly LumberBy Kara Harris · November 12, 2015
A Guide to the Production Process of Poly Lumber
The eco-friendly poly lumber used to construct our Amish outdoor furniture pieces is engineered from thousands of recycled plastic milk jugs and detergent bottles.
These plastic jugs are crushed into large bales at recycling facilities in the United States. As they are needed for use in outdoor furniture, the bales are shipped to manufacturers to be converted into poly lumber.
The process of creating poly lumber from recycled plastic includes the following steps:
- Bottles are knocked loose from the bales to be sorted
- Individuals scan and remove objects that are not a #2 plastic
- Jugs that pass inspection are ground into flakes and are double washed
- The jugs are melted and squeezed through a sieve to remove any stickers or debris
- What remains is cut into tiny pellets and mixed with dyes and a foaming agent*
- The mixture is melted and squeezed through a mold to form poly lumber
- As the poly lumber is produced it is cooled then cut to a standard length
*The foaming agent is added to the mixture to lessen the amount of bulk plastic needed, making the product lighter. This process gives the poly lumber more tensile strength with less plastic.
The eco-friendly poly lumber is then assembled by our Amish artisans using mortise and tenon joinery and stainless steel hardware to create your outdoor furniture pieces.
Because your outdoor furniture is constructed from poly lumber, it boasts the following features:
- Amish-made in the United States of America
- Lasts a long time and is virtually maintenance free
- Does not need to be treated, painted, or stained
- Engineered to withstand sun and salt exposure