COCOPEAT

MANUFACTURING

CHAPTER - 1
INTRODUCTION
1.1 UNIT SET UPED AT: POLLACHI

1.2 About the city

Pollachi is a town and a taluk headquarters in Coimbatore district, Tamil
Nadu state, India. Located about 40 km to the south of Coimbatore, it is
the second largest town in the district after Coimbatore. Pollachi is a
very popular Marketplace, with large markets for jaggery and vegetables
and is considered to be South India's biggest Cattle market.
Pollachi is well known for whole sale suppliers and exporters of fresh
coconuts and coconut products.
2

1.3 MISSION STATEMENT:

To achieve the leading position in the global growing media and

potting soil industry by providing world class products and services to
valuable customers across the world.
1.4 VISION STATEMENT:

To become the pioneers in the world of coir business

1.5 OBJECTIVES OF THE COMPANY:

The company has its objectives based on the general management

concept of SMART.
S SMART
M MEASURABLE
A ACIEVABLE
R REALISTIC
T TIME BOUND

To focus on cost reduction and technology up gradation in order to

become competitive in each line of business.
To constantly innovate and develop new products and services to
satisfy customer requirements.
To compete through speed, agility and flexibility in recognizing
and capturing opportunities in existing markets.

 To invest sufficiently to stay in the game but avoid premature

commitments.
1.6 QUALITY POLICY:

The company employs the concept of Total Quality Management.

The main aim of the organization is to obtain 100 % satisfaction of its
customers by supplying fine and high quality products.
1.7 COCO PEAT
Coco peat (cocopeat), also known as coir pith, coir fibre pith, coir
dust, or simply coir is made from coconut husks which are byproduct of other industries that use coconuts. Cocopeat primarily
consists of the coir fibre pith or coir dust which is obtained by
processing coconut husk and removing the long fibres. The cocopeat
which is obtained can hold large quantities of water, just like a sponge. It
is used as a replacement for traditional peat in soil mixtures, or, as a soilless substrate for plant cultivation.
Coir waste from coir fiber industries is washed, heat-treated, screened
and graded before being processed into coco peat products of various
granularity and denseness, which are then used for horticultural and
agricultural applications and as industrial absorbent.
Usually shipped in the form of compressed bales, briquettes, slabs or
discs, the end user usually expands and aerates the compressed coco peat
4

by the addition of water. A single kilogram of coco peat will expand to

15 litres of moist coco peat.

Coco peat is used as a soil additive. Due to low levels of nutrients in its
composition, coco peat is usually not the sole component in the medium
used to grow plants. When plants are grown exclusively in coco peat, it
is important to add nutrients according to the specific plants' needs.
Coco peat from Philippines, Sri Lanka and India contains several macroand micro-plant nutrients, including substantial quantities of Potassium.
This extra potassium can interfere with magnesium availability. Adding
extra Magnesium through the addition of Epsom salts can correct this
issue.
Some Coco peat is not fully decomposed when it arrives and will use up
available nitrogen as it does so (known as drawdown), competing with
the plant if there is not enough. Poorly sourced coco peat can have
excess salts in it and needs washing (check electrical conductivity of
run-off water, flush if high). It has a similar cation exchange capacity to
sphagnum peat, holds water well, re-wets well from dry and holds
around 1000 times more air than soil. Adding slow release fertilizers or
organic fertilizers are highly advised when growing with coco peat.

Common uses of coco peat include:

As a substitute for peat, because it is free of bacteria and most

fungal spores, and is sustainably produced without the environmental
damage caused by peat mining.

Mixed with sand, compost and fertilizer to make good quality

potting soil. Coco peat generally has acidity in the range of pH - 5.5
to 6.5. It is a little on the acidic side for some plants, but many
popular plants can tolerate this pH range.

As substrate for growing mushrooms which thrive on the cellulose.

Coco peat has high cellulose and lignin content.

Coco peat can be re-used up to three times with little loss of yield. Coco
peat from diseased plants should not be re-used.
1.7.1 APPLICATION OF COCO PEAT
Various application of coco peat is as follows: Lawns, nurseries & landscaping.
Golf constructors /sports field constructors.
Seedling nurseries/seed raising substrate.
As a soil conditioner.
As a potting mix.
Producers of growing media.
6

1.7.2 The various fearures of coco peat is as follows: A perfect multipurpose growing media for horticulture & floriculture.
Coco peat is viable alternative to peat moss.
High water holding/retention capacity.
Has high air filled porosity.
Stores and releases nutrients over extended periods of time.
Enhanced root penetration.
Allows efficient transfer of soil nutrients to roots.
Free from weed seeds or pathogens.
Coco peat is much lighter than soil, hence best suited for terrace gardens.
100% bio-degradable, organic and renewable resource.
Contains natural substances and beneficial microbes for plant growth.
Environmentally friendly and non-hazardous disposals.

1.7.3 Advantages of Coco peat:

The properties of Coco Peat make it resistant to bacterial and fungal growth.

Coco Peat holds water rather than shedding it like traditional peat does! It
holds 8-9 times its weight in water.

Coco Peat has the ability to store and release nutrient to plants for extended
periods of time. It also has great
oxygenation properties which is important for healthy root development.

Enhanced root penetration

Coco peat extends the life of compost.

Contains natural substances and beneficial microbes for plant growth

The coco peat has a tendency to expand in its volume, ie. Four to five times
from its original volume provided.

It has a pH of 5.2-6.8 which is neutral to slightly acidic. This makes it great

for alkaline garden soils.

Easy to use Just put your compressed Coco Peat brick in a container, add
4 quarts of warm water and let it sit until the water is absorbed, fluff it up and
you are ready to use Coco Peat!

Coco Peat can be reused for up to 4 years.

Coco Peat is very slow to disintegrate; it only begins to break down when it
is 10 years old, long term benefits.

It is very light and easy to handle.

It can be combined with any of the normal ingredients and use as a mixer or
a stand-alone product.

Weed free, pathogen free, insect free and odorless

Excellent medium for growing worms. Its actually good for them and
increases worm growth by 25%.

Has high air filled porosity

Much lighter than soil

Environment friendly and non hazardous

8

Mixed with sand, compost and fertilizer to make good quality potting soil

1.7.4 TECHNICAL SPECIFICATIONS

Water holding capacity

600 to 700%

Nitrogen

0.50%

Phosphate

0.03%

Potash

0.25%

Organic Carbon

10 to 12%

pH

6.5 to 7.5 %

Conductivity

Less than 0.5 milli/mhos

C/N Ratio

1:0.02

Total Organic Matter

75 to 85%

1.7.5 HOW TO USE COCO PEAT

The normal use of coco-peat in foreign country is the use of coco-peat

block form. Then if we need to expand the whole block later immerse the
block in a large tub capable of holding at least 25 litre of water. Remove the
wet expanded cocopeat that floats in the water. While continuing to add
water to the tub till the complete block is expanded. The cocopeat in the
bag are light in weight and easily transported to the nursery area or rain
shelter greenhouse. For a large grower who needs to expand large number
9

of cocopeat blocks, place the cocopeat blocks vertically with a distance of

about 1 feet between them. Spray water from a hose on the cocopeat
blocks while working on the blocks with hand to expand them into moist
cocopeat. Another method is to use machinery to crush the block into
powder and then use the dust.
The use of low compression cocopeat for absorption purposes, normally
we advise the farmers to simply break and crush the block into powder in
the palm of your hand. This method practical for those fragile cocopeat
either for locally produced cocopeat or imported cocopeat. The use of
cocopeat for potting mix we advise the user to mix the expanded cocopeat
with leaf mould or homemade organic manure in the ratio of 1:1. Add red
soil or sand in small quantities for large plants, otherwise the cocopeat will
not be able to hold the weight of the plants as they grow. Red soil tends to
compact over time (despite the cocopeat), so take care not to mix more
than one third of the mix. For germination, mix cocopeat, leaf mould and
sand in the ratio of 1:1:1. If you are using commercial organic manure, it
would be better to mix cocopeat and organic manure in the ratio of 10:1 as
commercial organic manures are often of high strength.

10

1.8 PRODUCTS/SERVICES
1.8.1 ENVIRONMENT FRIENDLY PRODUCTS

Preserving natural features can benefit both the developer and the
development. Nature-friendly development practices can add value to
property, protect natural resources and help organizational bottom lines
grow.
Coco peat products are 100% nature friendly and are made from
100% natural products of Coconut.

Coco peat
11

Coco peat Blocks

Coco peat Blocs

12

COCO PEAT USED FARMING

13

1.9 METHODOLOGY
RAW MATERIAL

(Coco peat)

WASHING

DRYING

Given to us
PROCUREMENT OF
RAW MATERIAL

14

SCREENING

TESTING

BLOCKING (5KG)

EXPORTS

1.10. Synthesis Of Raw Material

1.10.1 WASHING

The raw material for the process is obtained as the byproduct after the
extraction of coconut fiber from the coconut husk. Coco peat is obtained
from fiber factories, which is stored in yards completely free from seeds
weeds and other foreign particles. The raw material thus procured is
subjected to vigorous washing process to reduce the EC level. Preferably
2 cold washes followed by a hot wash.
1.10.2 DRYING

The washed material is then allowed to dry for about a day in order to
remove all the excess water .Fig 3.1 shows the open drying yard where
15

in heaps of the washed raw material is allowed to dry under the

influence of sunlight.

Fig 1.11 Drying yard

1.11.1 PROCUREMENT OF RAW MATERIAL

The raw material is thus procured from various parts of drying yards in
Pollachi where there is abundant supply of coco peat. Minerals are either
mixed in the raw material form or later in the manufacturing process.
1.11.4 SCREENING

Once complete drying of the raw material has been accomplished,

thorough screening is done to eliminate any unwanted lint and foreign
materials away from the raw material.

1.11.6 TESTING

16

The proto sample is created and it is then sent to the laboratory to

test whether the produced sample meets the requirements of the buyer. If
there are any issues then the process is rectified or else it is sent for bulk
production.
1.11.7 BAILING

After bulk production is effected the manufactured products are

sent in for bailing. The process of bailing is done in a block press which
has a production capacity of: 140-160 blocks / hour.
Block size : 300x300x100mm
Block weight : 5 Kg (+5%)

17

Coco peat 5 Kg block press

18

1.11.8 PRODUCTION

The initial product of the company will be 5 tonnes (5000kg) of

finished coco peat blocks per day. Later as per the order, the production
will be increased to 10 tonnes (10000kg) per day. The production will be
carried out in two shifts of 8 hours each to produce 10 tonnes (1000kg)
of coco peat per day.
1.11.8 EXPORT

Bailed material is then exported to various parts of the world.

19

CHAPTER 2
ORGANIZATIONAL SETUP

GOALS OF THE PRODUCTION DEPARTMENT:

To complete the orders received from customers on time.

To produce quality Coco Peat blocks exactly as per customer
requirements.
To use the production facilities and resources at optimum level and
thus minimize wastage.
2.5 MARKETING DEPARTMENT

The marketing department is will be in regular contact with the

exporters who purchase bulk of the finished coco peat blocks from us.

20

CHAPTER 3
SWOT ANALYSIS
SWOT

Analysis is

a strategic

planning method

used

to

evaluate

the Strengths, Weaknesses, Opportunities, and Threats involved in a project or in

a business venture. It involves specifying the objective of the business venture or
project and identifying the internal and external factors that are favorable and
unfavorable to achieving that objective.
A SWOT analysis must first start with defining a desired end state or objective. A
SWOT analysis may be incorporated into the strategic planning model. An
example of a strategic planning technique that incorporates an objective-driven
SWOT analysis is Strategic Creative Analysis (SCAN) Strategic Planning,
including SWOT and SCAN analysis, has been the subject of much research.

Strengths: attributes of the person or company those are helpful to

achieving the objective.

Weaknesses: attributes of the person or company those are harmful to

achieving the objective.

Opportunities: external conditions those are helpful to achieving the

objective.

Threats: external conditions which could do damage to the business's

performance.
21

Identification of SWOTs is essential because subsequent steps in the process of

planning for achievement of the selected objective may be derived from the
SWOTs.
First, the decision makers have to determine whether the objective is
attainable, given the SWOTs. If the objective is NOT attainable a different
objective must be selected and the process repeated.
The SWOT analysis is often used in academia to highlight and identify
strengths, weaknesses, opportunities and threats. It is particularly helpful in
identifying areas for development.

Fig 3.1 Swot Analysis.

3.1 IMPORTANCE OF SWOT ANALYSIS
The importance of SWOT analysis lies in its ability to help clarify and
summarise the key issues and opportunities facing a business. Value lies in
considering the implications of the things identified and it can therefore play a key
role in helping a business to set objectives and develop new strategies. The ideal
22

outcome would be to maximise strengths and minimise weaknesses in order to take

advantage of external opportunities and overcome the threats. For example, the
environment may present an opportunity for a new product but if the company
does not have the capacity to produce that product it may either decide to invest in
new plant and machinery or to just steer clear.
3.2 ADVANTAGES OF SWOT ANALYSIS
The biggest advantages of SWOT analysis are that it is simple and only costs
time to do. It can help generate new ideas as to how a company can use a particular
strength to defend against threats in the market. If a company is aware of the
potential threats then it can have responses and plans ready to counteract them
when they happen.
3.4 STRENGTHS
Cent percent support always from the coir board.
Technically classified Process wise buildings.
Well equipped machineries and processing technology.
Availability of transportation.
Close to cochin and Chennai ports.
Situated at a distance of 55 kms from the Coimbatore Airport.
Consists of a 24 hours Quality Control Lab.
Has the biggest network of raw material suppliers in pollachi.
3.5 WEAKNESSESS
23

 Drying process is affected by rains.

An alternative cost effective method for drying has not been found so far.

3.6 OPPORTUNITIES
Campaign for Green World
Coir Peat would be an ideal substitute for growing medium market.
Substrate Market

3.7 THREATS
Intense competition from Sri Lanka and Thailand.

24

CHAPTER 9
FUTURE PLANS
The following are the future plans of the company:
The company plans to broaden its business into the domestic market.
Increase and diversify their product ranges to coir mats and other allied coir
products.

25

CHAPTER 10
CONCLUSION AND RECOMMENDATION
Indian coir industry is an important cottage industry contributing significantly
to the economy of major coconut growing states and union territories like Kerala,
Tamil Nadu, Andhra Pradesh, Karnataka, Maharashtra, Goa, Orissa, Assam and
Pondicherry. About 5.5 lakhs get employment in this industry. The export is
around 5.5 Crores.
My focus on the industry is to study the unique products they are giving to the
market and the structure of their organization.
As far as my knowledge is concerned this industry is the only industry adopting
the new technology in manufacturing coco based growing media. This industry is
also going for expansion of home market through publicity and advertisement,
product diversification, adoption of new technology, R&D training for artisans
including women.

26

27