HISTORY OF COIR INDUSTRY
Coir is the only natural fibre that does not get cultivated solely to extract the coir whereas
jute and sisal are grown only to produce the fibres and in turn, the spun and woven
products. Fibres like jute, sisal, cotton etc are derived from short cropping plants whereas
coir originates from the near perennial coconut palm.
The coconut palm has been the subject of great adulation and admiration across the world
and down the ages. This is perhaps the only tree, which has a systematic recorded history
dating back to nearly 3000 years before the birth of Christ. Botanists say that the coconut
was domesticated in Neolithic, Stone Age, times. When the lst Ice Age has frozen much
of the waters of the world reducing the distance between the islands and continents,
seafaring tribes found it easy to move between landmasses. They carried coconuts for
food and water during their voyages and planted whatever was left over in their new
home.
1.2 Objectives and activities
The focus of the project was on coir wet processing technologies, and was directed towards
the research and transfer of technologies that would encourage further demand for
traditional coir products, for example, coir fibre, yarn and floor coverings (mats, matting
and carpets) by improving quality and enhancing appeal. The project required that these
technologies should be appropriate and cost effective, and would upgrade the production of
coir and yarn manufacture at village level.
OBJECTIVES:
Short-term
1. Soft coir fibres produced will result in softer and finer yarns and
will not hurt the fingers of women spinners.
2. Brighter fibres and yarns will produce diversified fancy products.
(at present only mats, floor coverings, and some room decorating
products geotextiles are produced).
3. The new bio process will be smoothly accepted by industry.
Long-term
1. Automatic spinning machines will be developed in coir sector.
2. Small scale industry will emerge into big industrial houses.
PROFILE OF THE COMPANY
NAME : Natural Coir Industries
ADDRES : S.F.No.108/2A Zamin Kottampatty road
Pollachi-phone-04259249459
PARTNER NAME : Mr.Saju George,,,Mr.Benny Mathew
CAPITAL : 5 LAKH
TOAL EMPLOPYEE : 50
MEN : 30
WOMENS : 20
RANGE OF PRODUCTS:
Natural Coir Industries offer wide range of coir products such as Coco Peat blocks, Curled
Coir rope, Coir Fiber Brown & White (Golden yellow) etc.
A. Coco peat
Coco Peat (Compressed Coir Pith) - Low EC
Dimension
Unit Weight
EC (1: 5 test)
PH
Moisture
Expansion
Compression
:
:
:
30X30X10 Cm
5 Kg
Below 1.0 mS/cm
5.5 to 6.5
10-15%
70 to 80 litres
Cocopeat
It is the binding material that comes from the fibre portion of the husk and is also known as
Coir pith or Coir dust is a by-product of extracting coir fibre from the husk of a coconut.
The coir dust is washed, heat treated, screened and graded before being processed into
various Cocopeat products for horticultural/agricultural applications and as industrial
absorbent. The compressed cocopeat is converted into fluffy cocopeat by addiing water.
One kilogram of compressed cocopeat will expand to 15 litres of moist cocopeat. The
Cocopeat by itself does not have any nutrients for plant growth. Necessary nutrients will
have to be added according to the plant that is to be grown exclusively in cocopeat.
Cocopeat is also mixed with sand, compost and fertilizer to make good quality potting soil.
In horticulture, cocopeat is recommended as substitute for peat because it is free from
bacteria and fungal spores and is produced without any environmental damage caused by
peat mining. Being a good absorbent, dry cocopeat can be used as an oil absorbent on
slippery floors. Cocopeat is also used as bedding in animal farms, poultry farms and pet
houses to absorb animal waste so as to keep the farm clean and dry.
B. Curled Coir Rope
Specifications
Quality
Moisture content% by mass
Total Impurity % by mass
Long Fiber content length above 150 MM
Medium Fiber content Length 100MM to 150MM
Short fiber content Length 50-100MM
Bit and baby Fiber upto and including 50MM
Sulphate content
Salt Content (PPT)
Weight
:
:
:
:
High quality - Decorticated
15% Max.
5 to 10%
15 to 20%.
25 to 30%
20 to 25%
10 to 15%
0.25% Max
0.6% Max.
30 to 35 Kg
Curled Coir Rope is made out of matured brown coir fibre. Curled Coir Rope is used for
various applications like making coir mattress, rubberized coir pads, coir cushions, carpet
under lays, seat cushions and for insulating drainage pipes. It is manufactured in coils of 30
to 35 kg bundles.
C.Coir Fiber Golden Brown
Main Specifications Of Coir
Quality
Moisture content% by mass
Total Impurity % by mass
Long Fiber content length above 150 MM
Medium Fiber content Length 100MM to 150MM
Short fiber content Length 50-100MM
Bit and baby Fiber upto and including 50MM
Sulphate content
Salt Content (PPT)
Pressed Bale weight
:
:
:
:
High quality - Decorticated
15% Max.
10 to 12%
15 to 20%.
25 to 30%
20 to 25%
10 to 15%
0.25% Max
0.6% Max.
100 to 110 kg and 150 kg
Coir Fiber - Brown is extracted out of matured brown coconut. It is used for various
applications like making Curled Coir Rope used in manufacturing coir mattresses,
rubberized coir pads, coir cushions, carpet under lays, seat cushions and for insulating
drainage pipes.. Brown coir pads are sprayed with rubber latex, which bonds the fibres
together (rubberized coir) and is extensively used as upholstery padding for the automobile
industry. Coir Fiber - Brown is also used for insulation and packaging. It is manufactured
in bales of 30 kg, 100 to 110 Kg and 150 kg.
D. Coir Fiber Golden Yellow (White)
Specifications
Quality
Moisture content% by mass
Total Impurity % by mass
Long Fiber content length above 150 MM
Medium Fiber content Length 100MM to 150MM
Short fiber content Length 50-100MM
Bit and baby Fiber upto and including 50MM
Sulphate content
Salt Content (PPT)
Pressed Bale weight
:
:
:
High quality - Decorticated
15% Max.
10 to 12%
15 to 20%.
25 to 30%
20 to 25%
10 to 15%
0.25% Max
0.6% Max.
100 to 110 Kg and 150 kg
Coir Fiber - White (golden yellow) is made out of immature green coconut husk. Coir Fiber
- White is used for various applications like making two ply yarn used in manufacturing
various coir products such as carpets. The major use of white coir is in rope manufacture.
Mats of woven coir fibre are made from the finer grades of bristle and white fibre using
hand or mechanical looms. White coir also used to make fishing nets due to its strong
resilience to salt water. It is manufactured in bales of 30 kg, 100 to 110 Kg and 150 kg.
Selection of Raw material
For manufacturing good quality of Coco fibre, we are using coconuts from the farms which
are very close to the riverside. For producing Coco peat, we are using the coir dust, which
is a by-product of extracting coir fibre from the coconut husk. Cocopeat is the binding
material that comes from the fibre portion of the coconut husk. The coir dust is washed,
heat treated, screened and graded before being processed into various Cocopeat products
for Horticultural & Agricultural applications and as Industrial Absorbent. Cocopeat is dried
and stored in cemented concrete yards with boundary walls to prevent it from mixing with
external seeds/weeds.
MANUFACTURING PROCESS OF COCOPEAT
Washing
The Raw Material is washed with fresh water to reduce the E.C. level. We have six
washing trays/tanks and we are using a specific technology for washing the material
evenly. Frequent Tests are done to confirm the E.C level of the material. A final will be
done on each lot of the washed material before drying process.
Drying
The washed material then dried to open sky in the cement yard The Drying Process is
undertaken in the vast spread cement yard (about 70,000 sq. ft.) which is free of foreign
particles surrounded by a compound wall. The material is being sent for drying to the
drying yard at specified moisture level. At this level the tests for confirming the moisture
are done. After confirming the moisture level, the material is screened by passing through
the screeners before it compressed.
Screening
Screening is done in revolving screeners, Bed type vibrators and sand separators to remove
the foreign particle, if any presented in the washed material. Then the material will be
ready for compaction.
Quality Control
The quality control is carried by experienced, highly qualified quality control Staffs. It is
ensured that each and every block manufactured in our factory is subjected to through
quality tests like E.C level, pH level and moisture etc.
We are maintaining quality in each level of production process from collecting raw
materials till the product shipment by testing EC, pH, Expansion, free of weeds and sand.
We have a separate quality control laboratory which is operated by highly qualified staffs.
Quantity
We are having good manufacturing capacities. Our current capacity is 500 tons of fibre,
250 tons of Curled Coir Rope and 500 tons of coco peat per month and is planning to
increase it in near future. Presently, we are manufacturing Compressed Cocopeat in 5 kg
blocks.
Container Loading
The above products are loaded in container by floor loading or by palletized loading. The
individual pallets gets sink wrapped. The loadable quantity is depends upon the products,
palletized or floor loading, size of container (20 ft / 40 ft). Normally we use Methyl
Bromide for container fumigation process.
Shipping
We are nearer to Tuticorin port, which is a famous port in South India and get connected to
major ports around the globe. We are closely working with our shipping agents to get best
freight prices and to deliver on time. We guarantee that our container reaches your
specified destination port safely, efficiently and effectively.
DEPARTMENTS
PRODUCTION DEPARTMENT:
that have ripened and fallen from the tree may simply be picked up off
The outer layers covering the coconut seed are processed and spun into fibers commonly
known as coir.
the ground. Coconuts still clinging to the 40-100 ft (12-30 m) tall trees are harvested by
human climbers. If the climber picks the fruit by hand, he can harvest fruits from about 25
trees in a day. If the climber uses a bamboo pole with a knife attached to the end to reach
through the treetop vegetation and cut selected coconuts loose, he can harvest 250 trees per
day. (A third harvesting technique, in which trained monkeys climb trees to pick ripe
coconuts, is used only in countries that produce little commercial coir.)
month by spreading them in a single layer on the ground and keeping them dry. To remove
the fruit from the seed, the coconut is impaled on a steel-tipped spike to split the husk. The
pulp layer is easily peeled off. A skilled husker can manually split and peel about 2,000
coconuts per day. Modern husking machines can process 2,000 coconuts per hour.
The materials used in Anar Coir Private Limited RCM division are broadly classified as:
Raw materials:
Latex, coir rubber chemicals, cloths and qualified fabrics, PU forms and threads.
General engineering items:
Electrical items, Mechanical items, spare parts and capital item tools.
PURCHASE PROCEDURE
Requisition
The power of approving material requisitions is with Anar Coir Private Limited head
quarters.
Purchase proposal
After purchase requisition has been approved by the head office, the order is placed.
Purchase order
After fixing the right supplier, purchase order is prepared and placed with proposed party.
The order rate, quantity, delivery schedule and terms of Payment will be mentioned.
Vendor rating
The responsibility lies with the Anar Coir Privalte Limited head office. Vendor rating is
done on the basis of product, price of the material and reports from the production
department in the case of latex or chemicals.
Receipt of materials
Materials are collected by the receipt store and the details will be given to the section for
inspection. Number of items passed and reason for rejection if any will be specified.
Receipts store will then prepare materials receipt report to be sent to the concerned section
i.e.; purchase and accounts. Original copy will be retained by the receipt store.
The materials used in Anar Coir Private Limited RCM division are broadly classified as:
Raw materials:
Latex, coir rubber chemicals, cloths and qualified fabrics, PU forms and threads.
General engineering items:
Electrical items, Mechanical items, spare parts and capital item tools.
PURCHASE PROCEDURE
Requisition
The power of approving material requisitions is with Anar Coir Private Limited head
quarters.
Purchase proposal
After purchase requisition has been approved by the head office, the order is placed.
Purchase order
After fixing the right supplier, purchase order is prepared and placed with proposed party.
The order rate, quantity, delivery schedule and terms of Payment will be mentioned.
Vendor rating
The responsibility lies with the Anar Coir Privalte Limited head office. Vendor rating is
done on the basis of product, price of the material and reports from the production
department in the case of latex or chemicals.
Receipt of materials
Materials are collected by the receipt store and the details will be given to the section for
inspection. Number of items passed and reason for rejection if any will be specified.
Receipts store will then prepare materials receipt report to be sent to the concerned section
i.e.; purchase and accounts. Original copy will be retained by the receipt store.
HUMAN RESOURCE DEPARTMENT
RM is the process of acquiring, training, appraising, compensating employees and
attending to their labour relations, health and safety and fairness concern. In other words
HRM is the people concerned dimension in management. Since every org is made up of
people, acquiring their services, developing their skills, motivating them to higher level
performance and ensuring that they continue to maintain commitment to the org are
essential to achieve organizational objectives. This is true regardless of the type of the
Organization, government, business, education, health, recreation and social action.
THE MAIN FUNCTIONS ARE:
Con
ducting job analysis
Plan
ning Labour needs and recruiting job candidates
Sele
cting job candidates
Con
ducting orientation and training programs for new employees
Man
aging wages and salaries
Pro
viding incentives and benefits.
App
raising the performance
Co
mmunication with employee (interviewing, counseling, discipline)
Trai
ning and developing managers
Buil
ding employee commitment
Human resource is the greatest of all resources RCM division have the total
CONCLUSION:
A substantial part of the initial targets for the project to develop technologies to produce
better quality and more attractive coir products with better consumer acceptance have been
achieved. Although there is still work to be carried out as a follow up to the various project
team activities, much more is now known of the chemical and biochemical aspects of wet
processing of coir as the result of CFC/FAO project investments.
Many of the achievements from coir bleaching research, developed within the project
programme at the CCRI, have been introduced into the coir industry of southern India. A
further reduction of chlorine containing bleaching agents in the recipes used is
recommended. The studies of the effects of bio-bleaching on industrial chemical
requirements should be continued. Appropriate effluent treatment and chemical recovery
systems should be developed.
Alternative dyestuffs, replacing the banned dyes used in coir dyeing and covering a whole
range of shades, have been evaluated and presented to the coir processing industry. Modern
technologies of coir dyeing have been introduced at various locations.
