Wednesday, January 29, 2014

Coir making process that Coir Mats Manufacturers should know

Coir Mats
There are two ways of making products made of coir. The first is the traditional method and the other is the mechanized methods. In the traditional process all the traditional processes of fiber extraction, spinning and twisting are followed. The outer layer of the coir fruit is kept in water for as long as six months. The coir or coconut is then hammered with an iron stick to remove the hard outer shell which now comes off easily in its wet state. People them separate the husk from the rest of the coconut. The fiber is refined by a special machine. In the mechanized process the coconut, after being put in water for months is put into the machine in which the fiber is automatically extracted. The extracted fiber is later soaked inside a water tank so that the fibers can become purified.

The process in detail:

After the coconuts are taken from the trees, the husks are soaked for many months so that the hard and brittle fibers can gradually become softened. This is done by putting the coconuts in baskets or nets and have those suspended over any water body. This is done for as much as six months. It is during this stage that microorganisms, along with the effect of air and water make the outer layer of the coconut soft enough to be taken apart by hand. The softening of the outer shell by microorganisms is called retting. However in the traditional practice it result in the pollution of rivers of any water body it is used in. New industrial practices of Coir Mats Manufacturers are not so damaging. In some plants special enzymes are added to the coconuts to make the outer shell and fibers soft by solubizing them.

In manufacturing plants and factories of Coir Mats Manufacturers, the coir fibers are cut into the required sizes. Rubber and latex is added to the coir surface so to make the surface rough. This is done so as people do not skid over mats. After this stage comes the creative part in which various kinds of colors are added to the mats. Mats may be on a single color or many colors at a time. Solid colors mats are popular in use. Patterns and designs of many variations are drawn on the mats. In the finishing stage the edge of the mats are sealed with rubber, tucked up and stitched. Mats do not have lint on the surfaces have ribbed effect on either side. After all these are done, the product is dispatched to the Coir Mats Suppliers. Coir Mats Suppliers then dispatch the products to retailers or to the customers directly.

Fibers that coir mats are made of are found in coconuts inside its hard outer shell as well as inside the hard inner shell. Coir fibers are composed of walls that are thick and are made of cellulose.  These fibers seems pale when young and become hard and either yellow or brown. The color added when a few layers of a naturally available substance known as lignin. Coir fibers can either be brown or white.