Unassumingly positioned at the entrance of homes and businesses, doormats may not seem like products that are rich in history or have intricate manufacturing processes. Yet, amongst the range of doormats available, there is one that stands out for its manufacturing process that is as impressive as the material itself – coir door mats! In this blog, we’re going to explore the origins, benefits, and unique manufacturing process of coir door mats from the coconut husk to the doormats that grace our entrances.

Coir, derived from the fibrous husks of the coconut, is a remarkable natural resource. The coconut palm, thriving in the coastal regions of South Asia and the Pacific, provides not only nutritious fruit but also fibres of great strength and durability. Coir matting has woven its way through history, dating back to the 11th century for uses beyond the simple doormat. It is cherished for its organic and fully biodegradable nature, making it a green choice for environmentally conscious consumers and businesses.

The Manufacturing Process

The manufacturing process of coir door mats is an art that combines traditional techniques with modern innovation. The fibres, once spun into yarn, are woven or tufted to create mats of various densities and patterns. Here are the steps involved:

  1. De-husking and Preparation

The journey of coir door mats begins with the harvesting of coconut husks. This process, undertaken with care to ensure the sustainability of coconut palms, separates the husk from the coconut’s edible part using a machete – a process known as de-husking.

  1. Soaking

Following de-husking, the husks are submerged in water, fostering bacterial growth that helps to break down the husk, leaving behind the raw coir. This soaking, traditionally in tidal waters, is an important step to soften the fibres and aid separation. Once soaked, the fibres are extracted and dried, to prevent decay and maintain the integrity of the matting.

  1. Sorting and Bundling

Through a combination of mechanical spinning and beating, the coir fibres are loosened and separated based on length. This selection process ensures that only fibres of optimal strength and durability are used for matting, whilst shorter fibres find use in products like mattresses.

  1. Weaving the Mats

The fibres are then spun into yarn, a process that can be done manually or with the aid of machines, depending on the scale of production. Following this, the yarn is woven or tufted to create a range of mats, with various densities and patterns.

  1. Customisation

Once assembled, the fibres can be coloured using natural or synthetic dyes to provide a selection of mats that will complement any décor. The dyeing process is carefully managed to ensure colour fastness and to minimise environmental impact. This customisation also allows for personalised touches, from welcome messages to brand logos, offering both functionality and aesthetic appeal.

Environmental Benefits

Coir door mats are not only notable for their look and functional qualities but also for their environmental credentials. As a natural and renewable resource, coir has a minimal carbon footprint. Its production process, predominantly reliant on natural processes and manual labour, further reduces environmental impact. Plus, at the end of its life, coir can be composted, returning valuable nutrients to the soil and completing its ecological cycle. It is also utilised in gardening as a peat compost alternative, offering a sustainable and environmentally friendly option. When shredded and mixed into garden soil, coir enhances water retention and aeration, providing an ideal growing medium for plants. This biodegradability stands in stark contrast to synthetic materials, which contribute to landfill and pollution.

Here at Commercial Matting, we are a leading manufacturer of coir door mats in the UK, offering a vast range of options to cater to all of our customers' needs. Our coir door mats are PVC-backed and available in a variety of colours, thicknesses, and sizes – they can even be purchased made-to-measure! For more detailed information, please visit our coir door mats page or contact us today on 01772 330051 and we will be happy to discuss your requirements with you.