Whenever you are getting the coir products with the best in quality, several steps are involved in manufacturing coir products from scratch. There are more steps to extract the coir products carefully with better quality to obtain several varieties from the fibre. India and Sri Lanka contribute the most in exporting coir products and coco-fibres; around 500,000 tonnes of coconut fibres are exported yearly.
Coco products have a significant impact on the commercial industry. They are extracted from coconut fibers that come from coconut husks, which are readily and abundantly available. As a result, these coco products serve as essential raw materials for commercial use.
This blog will clearly explain the steps involved in manufacturing the coir products from the fibre and the issues faced during extraction.
What are the Processes Involved in Manufacturing the Coir Products?
The Coir Products are derived from the husks of the coconuts. These coir products are made into spun Yarn, ropes, mats, floor coverings, and craftworks for aesthetic purposes. The coir products can be extracted in various methods, either in conventional methods or in modern ways.
The Coir products are playing as an essential raw material for manufacturing organic products, and they are becoming a new trend worldwide. Read How to Expand Your Coir Product Export Business to know more about the Coir product business further.
Before getting into the manufacturing of the coir products from the coconut fibres, let’s know what are the properties of the coconut fibres.
Properties of the Coconut Fibres
The brown coir fibre is more substantial, thicker, and can be used harder since it is hard to break. In contrast to the brown thread, the white fibre is softer, finer, and weaker when compared with the brown Yarn.
The coir fibres are mostly waterproof. The strength of the coir fibre depends on the thickness and density of the threads and moisture contents present. These fibres measure about 50-150 millimeters.
The Extraction Process
The Coco fibres can be extracted into two types of methods
- Traditional Methods
- Mechanical Methods
In the traditional process, the first and foremost steps for extracting the coconuts are separated from the coconuts by soaking the coconuts in the water for a long time. Then, these husks will undergo anaerobic fermentation, which softens the coconut husks and can be easily separated. These fibres are then washed, rinsed, cleaned gently, and obtained in the best quality to be easily made for spinning purposes.
In the mechanical process, the time taken to soak the coconuts is shorter than traditional methods. The husks are squeezed and crushed so that the fibres will get separated. This process will consume less time, and they are easily washed and cleaned. The more significant advantage of the mechanical process is that it is environmentally friendly and obtains higher quality products.
The coconut fibres undergo a process known as Retting. The healing process where the husks are placed and exposed to the environment induces the germs’ activity.
This process is where the pulp is decomposed partially, in which the fibres get separated from the husks, called coir piths. The freshwater is widely used to ripe the coconut husks, whereas the saltwater is used to ripe the green husks.
Spinning and Production
These methods extract the Coco fibres; these fibres are made to spin into yarns using the wheels. After these fibres are spun into yarns, they are bleached or coloured if necessary.
The yarns from the coco products can be made into various products such as brushes, brooms, materials for beds and mattresses and several other products. These spun coirs have industrial and domestic purposes as they are more versatile and are the basic raw materials.
Absorption Of Sodium
The coco fibres are to be softened with salt water. These coco fibres are made to be roughened and will not break down easily. Using salt water in these fibres will tend to smoothen the fibres. But there is a disadvantage of using these fibres with salt water: they will harm the crops. Henceforth, the fibres are soaked in fresh water for the plants to grow without any harm.
Time Taken for the Processing
The processing of the coir will take a long time. The matured brown coir is harvested from the nut and can be processed quickly without any time delay. On the other hand, the budding white husks require longer to be prepared. Some coco products are needed to be sterilised either with chemicals or steam. It is because these coir fibres are stored for a long time, even if it takes a year, which may be subjected to pathogens and pests.
The Final Process of Obtaining the Yarn
The coco fibres are then obtained in bristle form. These bristle fibres are rolled up and tightened in the loose bundles for shipment. These fibres are crushed and pressed in the hydraulic press.
Several techniques will vary from simple hand-spinning machines to fully automated spinning machines. These yarns can be shipped either to the final destination or multiple strands; those can be turned into strings and bundled, and then they are ready to be packed for shipment.
Applications of Coir Products
The Coir products are used for various purposes in personal households or commercial uses. Here are the applications of the coir products listed below.
Coir products are mainly used for filling up sofas, mattresses and automobile seating systems, such as auto-rickshaws, rail coaches, etc.
Controlling the Erosion
Using the coir discs by mixing with the soil together will prevent soil erosion during worse weather conditions.
Coir Products for Fishing Purposes
As the coir products have more durability and strength in nature, they are made to be woven and thus made into fishing nets.
Coco Peat Preparation
Since the coir products have enough capacity for water level management, they can be made into coco peats and mixed with the soil to nourish the plants healthier.
What are the Products Obtained from Coir?
The coir products which are obtained after manufacturing from the fibers are:
- Floor Coverings
The yarn is extracted from the brown fibres, which are more solid and durable than the white fibres. They are used in agriculture and serve as raw materials, making the finished products.
The ropes extracted from the coir yarns are stronger and more durable than any other.
These ropes are weaved together to form nets, which are widely used for fishing purposes. They will be inside water for a long time because they are water resistant.
The coir mats are used for daily needs as they are easier to wipe away dust and dirt. As they are rough, they withstand heavier feet and last more years.
These kinds of mats are widely used at the entrances of every house.
The coco coverings are similar to the coir mats but more significant. These coverings are more prominent, and it will be easier for the industries. Also, because of their rough nature, the coir coverings absorb the vibrations from the types of machinery.
The coir coverings are also used to remove the dust more efficiently, last an extended period, and are easy to maintain.
The coir products can also be used to make craft works such as ornaments, toys, pen-stands, key rings and several craftworks to add beauty to the surroundings.
The advantage of the coir craftworks is they are cost-efficient, more durable and for better aesthetics.
The coir products play a vital role in all aspects, from the household to commercial purposes. They are the basic raw materials for preparing commercial products such as brooms, ropes, nets, brushes, etc., as they are more durable and withstand several environmental conditions.
If you want the best quality of Coir products, SRS Bharath Exim is the perfect choice for fulfilling your needs, as we are the leading Coir Products Manufacturer. More experienced and professional employees will choose the coconuts from the groove without compromising the quality. Our mission is to export our coconuts worldwide and build a reliable relationship with exporters, importers and especially customers