BROWN COIR FIBER

1. The production process for  brown coir is a 2 - step process unlike the  white fiber. This is because brown husks are dry and very hard to break.

2. First the brown husks are fed into the auto feeder. The 1st decorticator  breaks the brown husks into small pieces as shown in the picture to the left.

3. This is then stacked on cement concreted floors and is heavily watered.  This is left undisturbed for  7 to 10 days.  The amount of watering done and the period for which it is left undisturbed  determines quality 

4. After 10 days , this crude fiber is fed into all the 4 decorticators to produce the brown Coir fiber.

COIR FIBER

The Outermost  covering of the coconut  is  called  the coconut HUSK .  Coir fiber is extracted from the coconut Husk . Coco peat is  the by-product obtained during extraction of fiber from Husk.  Coir fiber is used for making mats,  ropes , Geo-textiles etc.  Coir is broadly classified into 2 types.

1.  White coir fiber --   Coir extracted from Fresh Green coconut husks. Used for  making 2-ply yarn , Ropes etc.

2.  Brown coir fiber --  Coir extracted from matured Brown coconut husks. Used for making beds .

WHITE COIR FIBER

1. The Fresh green Husks  are Watered .  Amount of water that is sprayed on Husk  is one of the criteria for  fiber quality.

2. Husk is passed through all the 4 decorticators. 

3. All decorticators  are equipped with FRESH new  Knives so that the  Final pure fiber contains less impurities. 

​4.  The final  white fiber  that comes out is  sun dried on cement concreted floors. 

5. Once the fiber is dry  fiber is  compressed into 30 KG bales.  The 30 kg bales are then compressed into 120 KG bales and then loaded into containers.

Coir Fiber Quality 

1. Coir fiber is sold in Various grades based on application and also how much the  client is willing to pay for. 

2. First grade fibers either brown or white  has only Long length fibers  in the range of  10 to 20 cms. Has  very less impurities 

3. Lower grade fibers  are  produced by mixing  long length fibers with little amount of  Short length fibers also called BABY fibers as explained above. Has  more impurities than the 1st Grade.

4. picture to the left shows first grade White fiber.  and 2nd Grade brown fiber with more impurities.

CONTAINER LOADABILITY

1.  Coir  is generally exported in the form of   120 KG bales. which is compressed.

2. 180 to 185 bales  can be loaded into a 40 foot High Cube container.

3. Approx loadability is around 21.5 to 22 Metric tonnes.

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Coir  General production steps 

1.  Husks are fed into the production process  through an Auto feeder.

2.  The first decorticator  breaks the husk into small pieces.

3. Fiber is passed through three more decorticators. 

4. The final output is passed through a 12 mm Siever (16 feet in length) . This removes the coir pith from Fiber . 

5. During all stages of decortication , Coir pith is produced . This pith is sieved through another 12 mm Siever(16 feet in length). This  removes the Short length fibers from coir pith . These short length fibers are called BABY fibers.

6. The final picture shows the various blades used in the 4 decorticators.

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