HDPE Shade Net Manufacturing Process (Monofilament, Tape Yarn, Raschel Knitting)

HDPE shade nets are used everywhere in the UAE parking areas, construction sites, agriculture, gardens, warehouses, outdoor commercial spaces, and villa shading. But very few buyers actually understand how these nets are made and why certain types last longer, perform better, or offer stronger UV protection.

This guide explains the entire HDPE knitted shade net manufacturing process, covering:

• Monofilament vs tape yarn
• Raschel knitting
• UV stabilisation
• Density control
• Colour production
• Final quality checks

If you offer shade net installation or supply across the UAE, understanding this process helps you choose higher-quality products and avoid weak or short-life alternatives.

1. Raw Material Selection: 100% Virgin HDPE

The manufacturing process starts with 100% virgin High-Density Polyethylene (HDPE), not recycled material.

Virgin HDPE ensures:

• Stronger tensile strength
• Longer lifespan in the UAE heat
• Better UV stability
• Crack resistance
• Consistent colour and density

Brands like Dunet Shade Nets, supplied via Exclusive Tarps, use virgin HDPE for maximum durability.

2. Extrusion: Converting HDPE Into Filaments

Once HDPE granules are selected, they go through an extrusion process to form the fibres used in knitting.

There are two main extrusion styles:

2.1: Monofilament Extrusion

Monofilament yarns are produced by extruding HDPE into single, round, strong filaments.

Benefits of monofilament yarns:

• Stronger tensile strength
• Longer lifespan (5-7 years in UAE weather)
• Better UV stability
• Ideal for commercial and industrial shade nets

Link to product: Dunet Monofilament Knitted Shade Cloth

2.2: Tape Yarn (Flat Filament) Extrusion

Flat polymer sheets are extruded and then slit into thin “tape-like” yarns.

Benefits:

• More economical
• Flexible
• Ideal for agriculture, nurseries, and temporary shading
• Good airflow

Related products: Dunet Flat Filament Knitted Shade Cloth UL506, Dunet Flat Filament Knitted Shade Cloth SSGB6E

3. UV Stabilisation Treatment

UAE sunlight is extremely harsh, so shading fabrics must be treated with UV stabilisers during production.

UV treatment ensures:

• Colour does not fade
• Fibres do not crack
• The net survives 50°C+ summers
• Long-term durability outdoors

Premium shade nets, such as FR200 Fire-Retardant Netting, combine UV stabilisation with fire resistance.

4. Raschel Knitting: The Core of Shade Net Manufacturing

Most high-quality HDPE shade nets in the UAE are produced using Raschel warp knitting machines.

Why Raschel Knitting Matters?

It controls:

• Shade percentage
• Airflow
• Strength
• Fabric flexibility
• Wind resistance

Raschel Knitting Steps

1. Monofilament or tape yarn is fed into the machine.
2. Warp and weft structures are knitted together.
3. Knitting density determines shade percentage (30% to 95%).
4. Fabric rolls are produced in widths of 2m, 3m, 4m, and 6m.

For shade percentage guidance: See the blog How to Choose the Right Shade Percentage in Dubai

5. Heat Setting

To prevent fabric shrinkage, curling, or deformation in extreme temperatures, the knitted fabric goes through heat-setting.

Benefits:

• Dimensional stability
• Smooth finish
• Cleaner edges
• Balanced tension

6. Colour Masterbatch Mixing

HDPE shade nets are usually available in:

• Green
• Black
• Beige / Sand
• Dark Green
• Blue (custom)
• White (greenhouses)

Pigments are mixed during extrusion for long-term colour stability.

For detailed colour performance: Colour Guide: Green, Beige & Black Shade Nets

7. GSM & Density Calibration (Shade % Control)

Manufacturers adjust:

• Yarn thickness
• Yarn spacing
• Knitting pattern
• Stitch density

…to produce different combinations like:

• 120 GSM – 50% shade
• 160 GSM – 70% shade
• 200 GSM – 90% shade
• 230 GSM – 95% shade

Learn more here: GSM vs Shade Percentage Guide

8. Finishing, Rolling & Packaging

The finished shade net is:

• Cut into rolls
• Checked for knitting consistency
• Edge-reinforced
• Packed for shipment
• Tested for tensile strength & UV stability

High-grade options like Dunet Monofilament Knitted Shade Cloth undergo stricter QC standards, ensuring long-term durability.

9. Final Use-Case Classification

Before distribution, shade nets are labelled based on use cases:

Agriculture & Greenhouse

50%-70% | tape yarn or monofilament

Parking & Industrial

90%-95% | monofilament only

Privacy Fencing / Outdoor Walls

85%-95%

See our Shade Net Privacy Fencing 

Bird Control

Lightweight | 15mm-40mm mesh

View our Bird Netting

Frequently Asked Questions