INDUSTRY PROFILE History of Coir The history explains different stories on the birth of the golden fibre.

The first recorded history of coconut in the country dates back to Ramayana period.In the Valmiki Ramayana there are references of coconut in the Kishkindha Kanda and Aranya Kanda. It is reported that Ramayana was written by Valmiki sometimes in 3rd Century BC. Generally it is believed that coconut was introduced in India during the post-Vedic period. In the Valmiki Ramayana there are references of coconut in the Kishkindha Kanda and Aranya Kanda. It is reported that Ramayana was written by Valmiki sometimes in 3rd Century BC. Generally it is believed that coconut was introduced in India during the post-Vedic period. References have been made on coconut in Raghuvamsa of Kalidasa and Sangam literatures, which proves the antiquity of the coconut in India. But its origin in India remains disputed. But Marco Polo, the famous Arab traveler who visited India in the 13th Century called coconut "Indian Nut" and the logic for such a reference needs investigation by historians. Shri. P. K. Balakrishnan, a Kerala historian argues that organised coconut cultivation started in Kerala only after the arrival of the Portugese. Ropes and cordage, made out of coconut fibre have been in use from ancient times. Indian navigators, who sailed the seas to Malaya, Java, China and to the Gulf of Arabia centuries ago, had been using coir as their ship's cables. Arab writers of the 11 th Century AD referred to the extensive use of coir as ship's cables, fenders and for rigging. Facts record that there was coir industry in UK before the 2nd half of the 19th Century. During the year 1840, Captain Widely, in co-operation with Captain Logan and Mr. Thomas Treloar, founded the well-known carpet firms of Treloar and Sons in Ludgate Hill, England for the manufacture of coir into various fabrics suitable for floor coverings. The coir manufacturing industry producing coir mats, matting and other floor coverings, was started in India on a factory basis, over a hundred years ago when the first factory was set up in Alleppey in 1859 by the Late Mr. James Darragh, an adventurous Irish born American national. Enterprising Indians followed the trail blazed by this foreigner. Coir (from Malayalam kayaru - cord) is a coarse fiber extracted from husk, the fibrous outer shell of a coconut. Coir (koir) - The fiber obtained from the husk of a coconut, used chiefly in making rope and matting.

About Coir COIR is a versatile natural fibre extracted from mesocarp tissue, or husk of the coconut fruit Generally fibre is of golden color when cleaned after removing from coconut husk; and hence the name " The Golden Fibre".

Coir is the fibrous husk of the coconut shell. Being tough and naturally resistant to seawater, the coir protects the fruit enough to survive months floating on ocean currents to be washed up on a sandy shore where it may sprout and grow into a tree, if it has enough fresh water, because all the other nutrients it needs have been carried along with the seed. These characteristics make the fibers quite useful in floor and outdoor mats, aquarium filters, cordage and rope, and garden mulch. Structure of Coir Fibre The individual fibre cells are narrow and hollow, with thick walls made of cellulose. They are pale when immature but later become hardened and yellowed as a layer of lignin, is deposited on their walls. Mature brown coir fibres contain more lignin and less cellulose than fibres such as flax and cotton and so are stronger but less flexible. They are made up of small threads, each less than 0.05 inch (1.3 mm) long and 10 to 20 micrometres in diameter. White fibre is smoother and finer, but also weaker. The coir fibre is relatively waterproof and is the only natural fibre resistant to damage by salt water. Green coconuts, harvested after about six to twelve months on the plant, contain pliable white fibres. Brown fibre is obtained by harvesting fully mature coconuts when the nutritious layer surrounding the seed is ready to be processed into copra and desiccated coconut. The fibrous layer of the fruit is then separated from the hard shell (manually) by driving the fruit down onto a spike to split it (De-husking). Machines are now available which crush the whole fruit to give the loose fibres. Brown fibre The fibrous husks are soaked in pits or in nets in a slow moving body of water to swell and soften the fibres. The long bristle fibres are separated from the shorter mattress fibres underneath the skin of the nut, a process known as wet-milling. The mattress fibres are sifted to remove dirt and other rubbish, dried and packed into bales. Some mattress fibre is allowed to retain more moisture so that it retains its elasticity for 'twisted' fibre production. The coir fibre is elastic enough to twist without breaking and it holds a curl as though permanently waved. Twisting is done by simply making a rope of the hank of fibre and twisting it using a machine or by hand. The longer bristle fibre is washed in clean water and then dried before being tied into bundles or hunks. It may then be cleaned and 'hackled' by steel combs to straighten the fibres and remove any shorter fibre pieces. Coir bristle fibre can also be bleached and dyed to obtain hanks of different colors. White Fibre The immature husks are suspended in a river or water-filled pit for up to ten months. During this time micro-organisms break down the plant tissues surrounding the fibres to loosen them - a process known as retting. Segments of the husk are then beaten by hand to separate out the long fibres, which are subsequently dried and cleaned. Cleaned fibre is ready for spinning into yarn using a simple one-handed system or a spinning wheel.

Uses / Applications Brown coir is used in brushes, doormats, mattresses and sacking. A small amount is also made into twine. Pads of curled brown coir fibre, made by needle-felting (a machine technique that mats the fibres together) are shaped and cut to fill mattresses and for use in erosion control on river banks and hillsides. A major proportion of brown coir pads are sprayed with rubber latex which bonds the fibres together (rubberized coir) to be used as upholstery padding for the automobile industry in Europe. The material is also used for insulation and packaging. 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. Coir is recommended as substitute for milled peat moss because it is free of bacteria and fungal spores. Some Coir Facts COIR is a versatile natural fibre extracted from mesocarp tissue, or husk of the coconut fruit. The husk contains 20% to 30% fibre of varying length. After grinding the husk, the long fibres are removed and used for various industrial purposes, such as rope and mat making. The remaining material, composed of short and medium-length fibres as well as pith tissue, is commonly referred to as waste-grade coir. The waste grade coir may be screened to remove part or all of the fibre, and the remaining product is referred to as coir pith. The Wonders of Coir Moth-proof; resistant to fungi and rot. Provides excellent insulation against temperature and sound. Not easily combustible. Flame-retardant. Unaffected by moisture and dampness. Tough and durable. Resilient; springs back to shape even after constant use. Totally static free. Easy to clean.

WORLD SCENARIO Major producers Total world coir fibre production is 250,000 tonnes. The coir fibre industry is particularly important in some areas of the developing world. India, mainly the coastal region of Kerala State, produces 60% of the total world supply of white coir fibre. Sri Lanka produces 36% of the total world brown fibre output. Over 50% of the coir fibre produced annually throughout the world is consumed in the countries of origin, mainly India. Together India and Sri Lanka produce 90% of the 250,000 metric tons of coir produced every year. Srilanka is the largest exporter of fibre followed by Thailand and India. Product exports are mainly from India and to

some extend from Philippines and Sri Lanka, in the form of mats, mattings, rugs, carpets, needle felt, rubberized coir, geotextiles etc. The prominent markets are the North America, E.U. Countries, Australia, Japan, Korea etc. The traditional coir products like, coir mats, mattings, rugs, carpets still dominate the market as is evident from the export performance of India which is the major exporter of coir products. No reliable data is available about the consumption of coir fibre and products in the domestic markets of the producing countries. The non-availability of detailed data of production and consumption makes it difficult to assess the market potential, as well as the demand and supply position of coir products. It is more true of the developing countries to which coir exports have been extremely low, although one would expect an expanding market for the product. Here is scope for development of coir industry in the coconut growing countries of Asia Pacific. But, there has not been much of an institutionalized effort on the part of international development agencies to promote coir industry, amongst the major coconut producing countries of the Asia-Pacific Region except in India, Sri Lanka and may be Philippines. The Asian and Pacific coconut community (APCC), which is an independent regional intergovernmental organization, now consisting of 14 countries, have more or less focused its entire attention to the development of coconut farming, development of coconut based products like coconut oil, copra, desiccated coconut, cream, powder etc. with noteworthy achievements. But the coir industry some way or other has not been able to draw serious attention that it deserves, from the APCC. In India alone, about half a million people depend on this industry for their livelihood. This is an agro-based sector with export potential which can provide employment particularly to the rural folk at affordably low levels of investment. Development of this industry will in turn help improve the livelihood and food security of the people engaged in it. A study held in the midnineties has identified rubberized coir, needle felt, geotextiles and coir peat as products with good scope for promotion. Rubberized coir has application as vehicle and furniture upholstery material, mattresses, packaging material, and even for acoustic and insulation purposes besides its use as geotextiles. Coir needle felt is generally used as mattress material, plant liners and other high end garden articles. This is also being used as insulation pads, geotextiles and organic mulch. Coir geotextiles are used in different forms like woven, non-woven, stitched blankets etc. for various soil bioengineering applications Geotextiles is in fact an engineering material rather than a consumer product so much so it requires a technology based promotion strategy. The characteristics of specific erosion problem, selection of suitable techniques and coir geotextiles materials including vegetation, testing and analyzing the wide array of products and their application are all relevant for a successful technology based promotion of coir geotextiles. The growing awareness about the need for protecting soil, especially the topsoil which sustains life on earth, in the developed countries as well as in the developing countries is a welcome sign. The Coir Geotextiles producing countries can jointly embark on generic promotion of the product in a mutually beneficial manner. The wide market for a long term biodegradable geotextiles which is legitimately that of coir geotextiles should be exploited sooner than later through co-operative efforts. This would ensure bulk utilization of raw material and generation of new employment opportunities.

Export of Coir and Coir products from India during the period 2006-07 recorded an all time high with impressive increase in both quantity and value. In value terms, the coir exports stood at Rs.605.17 crores attaining 19% growth in value by exporting 1.69 lakh ton of Coir Products. The increase recorded in quantity was 32728 ton and in value it is Rs.96.72 crores. The number of countries importing coir and coir products from India increased to 97 from 91 last year. U.S.A, U.K, Germany, Netherlands, Italy and Belgium are the major markets for coir products. Among these, United States continues to be the single largest market accounting for 37% of the total export and European countries together imported more than 41%. U.S.A stands first with regard to import of major share of handloom mats, tufted mats, coir geo textiles and power loom mat. The biggest market for coir yarn and coir pith is Netherlands and for coir handloom marketing UK stands first. STATE SCENARIO Kerala and the Coir Industry The history of Coir and its association with the state of Kerala dates back to the 19th Century. Sandwiched between the Western Ghats on the east and the Arabian Sea on the west, Kerala is one of the most beautiful States in India. A tropical paradise of waving coconut palms and wide sandy beaches, this thin strip of coastal territory slopes down from the mountain Ghats in a cascade of lush green vegetation and varied fauna. One of the most commonly seen tropical trees in Kerala is the Coconut tree. In fact, even the name Kerala (Kerlam in Malayalam) is derived from this tree (Kera in Malayalam language means Coconut and Alam means Land, thus Keralam = Land of Coconut). Everything from Kerala's culture to its dishes is evolved around the Coconut tree. Coir industry is one of the major traditional industries in the State and second only to agriculture in terms of employment. It provides employment to around 4 lakh persons, of which 84% are women. With 10.05 lakh hectares under coconut cultivation, this accounts for 45% of the net cropped area in the State. The Coir industry in the State is mainly concentrated in the regions of Alappuzha, Kayamkulam, Chirayinkeezhu, Kollam, North Parur, Thrissur, Kozhikode, Kannur, Ponnani and Vaikom. Handloom mats, Tufted mats, Power loom mat, Coir fibre, Coir pith, Rubberized coir and Coir geo textiles, Handloom matting and Coir yarn are the major items of export. Alleppey (Alappuzha in Malayalam) is the nerve centre of Kerala's famous Coir industry. Here, one can see coconut husks being beaten into fibre for making beautiful mats and other coir products. Both men and women are actively involved in the production of Coir. The women are mainly involved in the yarn spinning sector and the men in the product-weaving sector. Coir Industry enjoys the status as the largest Cottage Industry in the State of Kerala, giving employment to over a million people. Kerala also has a very fine natural harbor located at Cochin ( Kochi). From the ancient times itself Cochin had found a place in the minds of Europeans as a trading centre because of its port and spices.

Some of the historical monuments left behind by the early travelers at Cochin are the Chinese fishing nets that were introduced during the medieval ages by traders from the Court of Kublai Khan. St. Francis Church considered as the oldest European church in India was built by the Portuguese sailor Vasco Da Gama during the period 1503 to 1524. The Jew Synagogue built by early Jewish settlers in the period 1568 is another notable historical monument. COIR PRODUCTS 1. COIR FIBRE Coir Fibre is extracted from the fibrous outer cover of the fruit of the Coconut palm, with or without retting. Coir Fibre is graded based on its nature of extraction, colour, presence of long and short fibres, impurities etc.
BRISTLE FIBRE

RETTED FIBRE

UNRETTED FIBRE

2. COIR YARN Coir Yarn is generally of 2 ply, spun from coir fibre by hand as well as with the help of traditional ratts, fully automatic spinning machines etc. The Coir yarn is of different qualities/grades based on the quality of fibre used, the nature of twist, presence of impurities etc.

Available in different forms like hydraulically pressed bales, spools bobbins, dholls, balls etc. cut length for various industrial and agricultural purposes.
Bobbins & Export Hanks

3.COIR MATS & CREEL MATS Creel mats are manufactured both on handlooms and power looms. They are specially noted for their low pile height. The yarn for the pile structure is released from the beam in the course of the weaving process. The pile structure is obtained by suitable positioning of the coir yarn in the fabric structure with the use of grooved rods and cutting the yarn passing over the rods with a sharp knife. These are available in solid shades, stripes, mottled, stenciled and also tile patterns. 2-chain creel mats and 3- chain creel mats are available in this category. 3-chain creel mats have a firmer structure than 2-chain creel mats. Special type of mats with jute twine sold under the name 'carnatic mats'.
Beach Creel Mats

Power loom Creel Mats

Vycome Creel Mats

4.COIR MATS-FIBRE MATS Coir Mats are made on handlooms, power looms or frames and with or without brush. Creel Mats are known for its thin brush. Rod Mats for thick brush and Fibre Mats for compact brush. Latex/rubber backing makes the mats non-slip. Available with woven or stenciled designs and bevelled patterns for use in interior or exterior door fronts.
Fibre Mats

5.COIR MATS- ROD MATS,CORRIDOR MATS, CARNATIC MATS Coir Mats are made on handlooms, power looms or frames and with or without brush. Creel Mats are known for its thin brush. Rod Mats for thick brush and Fibre Mats for compact brush. Latex/rubber backing makes the mats non-slip. Available with woven or stenciled designs and bevelled patterns for use in interior or exterior door fronts.
Rod Mats

Carnatic mats

Corridor Mats

6.COIR MATS - LOOP MATS,MESH MATS, SINNET MAT Coir Mats are made on handlooms, power looms or frames and with or without brush. Creel Mats are known for its thin brush. Rod Mats for thick brush and Fibre Mats for compact brush.

Latex/rubber backing makes the mats non-slip. Available with woven or stenciled designs and bevelled patterns for use in interior or exterior door fronts.

7.COIR MATS - GYMNASIA MATS, MATTING MATS, ROPE MATS Matting mats Coir mattings are cut into the sizes of mats and the edges are finished with all around rubber edging or tucked-in edges. Latex backing or rubber sheet backing are also resorted in the manufacture of these mats to give a firm look for the product. These are mostly available in all fancy shades, woven patterns etc.

8.COIR MATTINGS - FOUR TREADLE WEAVE, BASKET WEAVE Made on traditional handlooms or powerlooms. Available in natural beach, solid colours and a multitude of designs/patterns made by weave and colour combinations and with or without latex backing. Quality of the matting is determined by the type of yarn and weave used. Mainly used as floor coverings and floor runners for furnishing stairs/corridors. Also used for wall panelling, ceiling, lining and echo-control.

9.COIR MATTINGS - RIBBED MATTING, MULTISHAFT MATTING, CRICKET PITCH MATTING Made on traditional handlooms or powerlooms. Available in natural beach, solid colours and a multitude of designs/patterns made by weave and colour combinations and with or without latex backing. Quality of the matting is determined by the type of yarn and weave used. Mainly used as floor coverings and floor runners for furnishing stairs/corridors. Also used for wall panelling, ceiling, lining and echo-control.

10.MATTING RUGS Coir Mattings are cut to rug size, ends bound, tucked in, fringed or rubber sealed for use as area rugs. Also available with cotton/tapistry bound and with or without latex backing.

11. NON WOVEN PRODUCTS

12. NON WOVEN MATS Made on traditional handlooms or powerlooms. Available in natural beach, solid colours and a multitude of designs/patterns made by weave and colour combinations and with or without latex backing. Quality of the matting is determined by the type of yarn and weave used. Mainly used as floor coverings and floor runners for furnishing stairs/corridors. Also used for wall panelling, ceiling, lining and echo-control.

13. COIR GEO-TEXTILES Coir Geotextiles protect land surface and promote quick vegetation. Geotextiles are a wonderful treasure of natural echo friendly, erosion control blankets in woven and non-woven preparations. Totally biodegradable, geotextiles help soil stabilization and renew vegetation in varying slopes.

14. COIR PITH A spongy material that binds the coconut fibre in the husk, coir pith is finding new applications. It is an excellent soil conditioner and is being extensively used as a soil-less medium for agrihorticultural purposes. With its moisture retention qualities, coir pith is ideal for growing anthuriums and orchids. Available in raw form or converted into organic manure.

15. GARDEN ARTICLES Products made out of Coir fibre. From poles to plant pots to hanging baskets, coir makes just about every accessory that is essential for modern day gardening. Coconut husk chips also are widely used in horticultural applications.

16. OTHER PRODUCTS

Curled Coir Needled Felt

Hand Knotted Netting

Coir Ply Articles

Coir Ship Fenders

Coir Braid

Coir Rope

Coir Tea Leaf bags

Coir Brushes