How Is Poly Outdoor Furniture Made-001

How is Poly Outdoor Furniture Made?

Data reveals that over 7 billion tons of plastic waste are produced worldwide. Regrettably, less than 10% is recycled. People practicing eco-friendly ways seek ways to reduce plastic pollution. Consequently, a man devised an incredible idea to minimize plastic waste and recycle it.

Doug Rassi, the CEO and founder of Polywood, introduced the idea of crafting outdoor furniture with recycled plastic.

Since then, poly furniture has gained traction in various settings. People are increasingly turning to this furniture type because they find it an ideal replacement for wood and metal furniture.

Because the former is prone to damage and the latter is subject to corrosion, it makes sense why poly outdoor furniture is a popular consumer choice.

However, because businesses lack information about this furniture type, it keeps them from investing in an opportunity that can make them a killing. This article aims to address everything about poly outdoor furniture, from the production process to its benefits.

Moving forward, we’ll also introduce reliable and credible poly furniture manufacturers.

What Is Polyethylene?

The word “Poly” refers to high-density polyethylene (HDPE) – a plastic-type popular for its robustness. It can endure extreme temperatures and can be recycled pretty easily. Further, it can be used in many applications because of its crystalline structure.

Perhaps this explains why manufacturers produce tons of polyethylene annually. Four popular types of polyethylene include.

  • Low-Density Polyethylene (LDPE). This material is a perfect fit for plastic wraps and shopping bags.
  • Linear Low-Density Polyethylene (LLDPE). Its manufacturing requires less energy. Besides, manufacturers can change its properties, which is a plus. It allows them to boost the strength of LLDPE.
  • High-Density Polyethylene (HDPE). Its high crystalline structure makes it strong and stiff. Manufacturers typically use it to make juice and milk cartons. Further, trash cans and chopping boards are other common applications.
  • Ultrahigh Molecular Weight Polyethylene (UHMW). It is a denser polyethylene, and manufacturers use it to design high-performance materials.

What Is Poly Outdoor Furniture?

Poly outdoor furniture refers to the furniture designed using poly lumber. Manufacturers produce it from high-density polyethylene (HDPE) collected from post-consumer waste like plastic containers, bottles, and jugs.

Then, they clean, sterilize, and disinfect this plastic before making lumber boards. This makes it suitable for designing furniture and other applications where individuals typically choose wood.

This way, the artisans keep the plastic from making its way to landfills. Instead, they use an environmentally friendly process to produce poly lumber and design attractive furniture.

It wouldn’t be wrong to say that this streamlined manufacturing process benefits the environment and humans.

First, it keeps HDPE from contributing to landfills. Second, it reduces the need to cut down trees to use wood – in fact, it offers an excellent alternative for various wood applications.

Third, poly lumber allows for customization, from plastic tables and chairs to deck sofas and lawn swings.


The Production Process of Poly Outdoor Furniture

The production process of poly outdoor furniture speaks volumes about how it favors the environment by minimizing plastic waste and utilizing it for the better.

We’ll explain how we take post-consumer trash and turn it into stunning, long-lasting poly outdoor furniture.

Play Video about How to Make HDPE Recycled Plastic Outdoor Furniture & Why We Make It

Plastic Collection

To begin with, we collect the plastic that otherwise finds its way to the landfill or the ocean, negatively affecting the soil and marine life. Hundreds of thousands of plastic waste are collected to produce the furniture.

Manufacturers collect plastic bottles, containers, and jugs and take them to the factory. The plastic arrives in the form of massive bales, each containing around 10,000 containers.

Manufacturers then pass this plastic through a shredder. This equipment has two main functions: to shred the plastic into a smaller size and to remove any foreign materials accompanying the plastic bottles.

The plastic waste is then ground and squeezed into tiny plastic beads.

These beads are typically stored in silos so long as they aren’t used. When wanting to utilize them for production, we add UV stabilizers and color to make beads fit for designing robust poly lumber.


The Production Process

The official production process has several stages to ensure the best possible outcome. Here’s a quick look into the different stages of poly outdoor furniture manufacturing.

  • Plastic plate production. The first stage involves making the plastic plates – also called poly lumber. Transforming the beads into poly lumber makes cutting, molding, and shaping easier. The plastic plates are formed using heavy-duty machines. However, before we move to mold, each plate undergoes careful examination to ensure proper thickness and color consistency. Further, we tend to eliminate any defects spotted at this stage.
  • Molding. As the name implies, the molding process is about shaping the lumber into varying furniture parts. Of course, each piece of furniture is constructed differently. Therefore, the molding process that goes into making furniture varies. For instance, poly chairs require leg molding, but a lawn swing doesn’t need one.
  • Polishing is essential to beautify the molded furniture parts. Besides, it ensures that the furniture retains its appeal after years – a reason why consumers seek this furniture type.
  • Drilling. The last step involves drilling holes to join different furniture pieces. While the initial stages require cautious handling, the last step also needs careful work for a successful outcome. Manufacturers drill perfect holes to assemble the furniture pieces seamlessly.


There’s no point in putting effort into the production process if the packaging is compromised by the end of the day. Quality packaging ensures that the furniture reaches the site safely.

It also complements the hard work that goes into manufacturing poly furniture. Our craftspeople carefully pack various furniture pieces before sending them.



And finally, we ship our quality poly furniture to various locations. Numerous business owners reach out to us on receiving poly furniture orders.

We aim to bring more awareness regarding the benefits of this furniture type and how consumers are rapidly shifting towards it to fulfill their outdoor seating needs.


Poly Outdoor Furniture Benefits

Anyone unfamiliar with poly outdoor furniture would likely hesitate to consider one. Yes, the furniture offers a variety of color and design options, but these reasons aren’t convincing enough to encourage consumers to purchase.

But the unique production method and makeup of polyethylene make it the right fit for outdoor furniture. Further, because consumers are becoming more aware of environmentally friendly brands, they prefer purchasing from companies offering related products.

So, this furniture has a lot in store for you and your consumers. Here’s what sets it apart from other types of furniture.

Low Maintenance

Maintenance is a significant issue that comes with any outdoor furniture type. The furniture placed on the deck or patio is exposed to several environmental stressors.

Therefore, metal furniture rusts over time. Besides, colored furniture is prone to fading. Fortunately, poly outdoor furniture eliminates the trouble because it requires little to no upkeep. You do not need to clean and paint poly furniture to retain its look for end consumers.

This furniture is naturally beautiful and does not require occasional coating and painting to make it visually appealing. A wipe is all it takes to maintain its luminous appearance.

Nothing is more attractive for end consumers than furniture that requires minimal maintenance; luckily, poly furniture caters to their needs.

Consumers can say goodbye to recurring maintenance costs and scrubbing furniture with harsh detergents. Instead, soap and water can help eliminate any dust or debris hidden in the nooks and crannies of their outdoor furniture.

Besides, retailers can leave this furniture out on display without worrying about the weather or aging factors. The robust material of this furniture is resistant to stains, moisture, and severe weather conditions.


Environmentally Friendly

Poly outdoor furniture is made from plastic, but that doesn’t indicate it isn’t helpful to the environment. Contrary to popular belief, this furniture type promotes eco-friendly practices and utilizes plastic waste strategically. Here’s how else it benefits our mother planet.

  • Minimize wood usage. Furniture is made from wood, and wood comes from trees. Unfortunately, industries manufacturing wood furniture cut down trees, negatively affecting the environment. Poly lumber is an excellent alternative for wood. It reduces the need to cut trees, promoting a healthy environment.
  • Recycle plastic waste. Poly outdoor furniture keeps plastic waste from entering landfills and the ocean. Instead, it recycles plastic containers and bottles to make attractive furniture for consumers to utilize.
  • Does not discharge chemicals. Unlike Polyvinyl chloride (PVC), HDPE does not leach chemicals into the soil. Typically, PVC furniture requires chemical sealing that enters the ground, killing the living organisms. Poly lumber doesn’t require chemical sealing, making it an ideal fit for the environment.


Wood and metal furniture have numerous drawbacks. For instance, wood chairs and tables outside the building absorb moisture during rainy days. This makes them susceptible to cracks and breaks.

Metal, on the flip side, corrodes over time. Fortunately, poly outdoor furniture outpaces other furniture materials due to its strength and durability. It does not rot, nor does it break. Besides, it doesn’t fade or become unsightly like wood.

The highly resistant material can withstand environmental stressors without breaking, cracking, or fading.

Further, it tackles rodent and termite attacks. Many pests love wood and utilize it as a nutritional source. However, they do not attract plastic furniture, making it suitable for placing outdoors.

Lastly, it handles pressure without breaking or bending. Consumers do not need frequent repairs and replacements to keep their poly furniture in shape.



Because “outdoor” furniture is placed outdoors, it’s evident it’ll bear all external factors, from high winds to rainstorms and hail to snowstorms. As such, it isn’t surprising that outdoor furniture fades and breaks over time.

In fact, wood furniture lasts hardly a few months. Soon, consumers pay for repairs to keep their furniture fit for use. Besides, they must seal, coat, and paint their furniture to keep it attractive.

Metal furniture bends and rusts with each passing day, and regular maintenance is needed for optimal performance.

Therefore, consumers seek furniture that stands the test of time and requires minimal maintenance. Poly outdoor furniture has lived up to the expectations of thousands of consumers. More and more people are purchasing this furniture because of its durability.

The UV ray and moisture-resistant poly furniture can be kept outdoors without worrying about its appearance.

Further, the poly furniture packs durability with an ideal weight. It isn’t like the ordinary lightweight furniture that falls in the event of strong winds. Instead, it stands well against harsh weather and heavy winds.

Color Variety

Poly outdoor furniture comes in various colors. Endless hues and shapes provide countless options to consumers. This means they can combine their favorite colors and make something unique for their home.

Wood and metal furniture typically offer limited colors. Besides, consumers do not have an option to combine numerous colors for the desired outcome.

Poly outdoor furniture satisfies customer needs by letting them choose their preferred color schemes. For instance, consumers often desire a specific color combination for their backyard. They typically prefer dark colors to complement their lush green backyards.

Further, a few customers like light colors for their deck and patio to stand out against their home exterior. Because every homeowner has a different outdoor, the choice of furniture varies significantly. Poly outdoor furniture manufacturers cater to such needs and can help meet your consumer needs.

Besides, you can also take care of the client’s branding needs. For instance, companies often have limited colors; you can provide the furniture to fulfill their business goals.



The drastically rising demand for poly outdoor furniture encouraged us to design striking and quality furniture for the outdoors. We are one of the leading manufacturers of poly outdoor furniture in our community.

Because we aim to benefit businesses seeking to offer quality to consumers, providing fine furniture at an affordable price is our ultimate goal.

You can become a reliable poly furniture supplier by collaborating with us. Our skillful workforce pays attention to detail when manufacturing the furniture. With over 15 years of experience in the field, we have the knowledge and expertise to produce various furniture pieces.

Lastly, our professionalism and experience have taught us how to serve customers better. We’ve improved our processes to provide a better supply chain, from upgrading our shipping process to revamping the order details.

You would not experience any unforeseen issues working with us because we go the extra mile to implement quality services to take your business to new heights.

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