How are Coir Doormats Extracted and Made In to High Quality Door Mats?
The tough, fibrous material known as coir comes from the outer husk of the coconut fruit of the coconut palm. The round, brown coconut that you are familiar with is only the inner seed of the fruit—there is actually a very thick protective layer that surrounds it. This outer layer must be removed from the coconut before it is processed into coir.
- The coconut is de-husked using a machete—the sharp blade is driven into the husk repeatedly in order to separate it from the edible inner seed.
- Once the entire husk has been removed, it is soaked in water for a period of time, which encourages natural microbial growth. These bacteria eat away softer parts of the coconut, only leaving raw coir. The raw coir consists of both usable fibers and loose material called coconut dust, or coir pith. This filler material is not suitable for coir matting and is usually discarded or made into fertilizing mulch.
- The coir then undergoes an intensive beating process in a fast-rotating drum, which are equipped with sharp steel arms. The repeated impact of these metal bars loosens the fibers.
- The loosened fibers are placed through a slower rotating drum, which separates the fibers by length. Small length fibers are still too short to be made into mats, so these lengths of fibers become mattress padding material. Only medium length coir fibers are made in to coir doormats, while the longest fibers are reserved for making durable twine and rope.
- Coir fibers that are suitable length for door mats are gathered, bundled, and assembled into a variety of coir mats of all shapes, sizes, and designs!
Coir fiber is extremely durable and weather resistant, which is ultimately what makes it so ideal for outdoor entry mats. Exterior mats must be able to withstand a range of natural weather, from harsh sunlight and temperatures to pounding rainfall. Coir fibers are definitely strong enough for that! The natural brown color variation also gives them a quaint, rustic feel, which is appealing to many home-decor conscious buyers. Unlike factories here, these coir-producing facilities operate in a small village fashion—so ultimately, these highly durable coir door mats are the results of entirely sustainable, eco-friendly processes! The production processes show that high quality door mats can also be eco-friendly, long lasting, and very affordable. Made by small production artisans, coir matting adds a charming feel to any front door.