PROCESS OF COIR FIBER
Coir fibers are categorized in two ways. One distinction is based on whether they are recovered from ripe or immature coconut husks. The husks of fully ripened coconuts yield brown coir. On the other hand, white coir comes from the husks of coconuts harvested shortly before they ripen. The white color fiber is softer and less strong than brown coir.
The other method of categorization of fiber is based on the length. Both brown and white coir consist of fibers ranging in length from 10-30cm. Those that are at least 20cm long are called bristle fiber. Shorter fibers, which are also finer in texture, are called mattress fiber. A 300g coconut husk yields about 80g of fiber, one-third of which is bristle fiber.
WE’RE POPULAR IN COCONUT COIR-BASED MARKET GLOBALLY
COCONUT PROCESS
Coconuts that have ripened and fallen from the tree may simply be picked up off the ground. Coconuts are harvested by human climbers or uses a bamboo pole with a knife attached to the end to reach through the treetop.
Ripe coconuts are husked immediately, but unripe coconuts may be seasoned for a month by spreading them in a single layer on the ground and keeping them dry.
STEPS AT CEYLON BRUSH TECH (PVT) LTD
Ceylon Brush Tech (Pvt) Ltd receive and collect husk from local distributors. To remove the fruit from the seed, some use locally manufactured machine operates by the human. Husking machines can process 2,000 coconuts per hour. “
Retting is a curing process during which the husks are kept in an environment that encourages the action of naturally occurring microbes. This action partially decomposes the husk’s pulp, allowing it to be separated into coir fibers and a residue called coir pith. Freshwater retting is used for fully ripe coconut husks in large tanks prepared by cements with well secure locations within the factory premises.
Ripe husks can be processed in crushing machines after being retted for only seven to 10 days. Immature husks can be dry milled without any retting. After passing through the crushing machine, these green husks need only be dampened with water or soaked one to two days before proceeding to the defibering step.
COCONUT PROCESS
Traditionally, workers beat the retted pulp with wooden mallets to separate the fibers from the pith and the outer skin. But Ceylon Fiber use locally manufactured, motorized machines which have been developed with flat beater arms operating inside steel drums.
Separation of the bristle fibers is accomplished by the machine consisting of a rotating drum fitted with steel spikes. Separation of the mattress fibers from the pith is completed by washing the residue from the defibering process. Those fibers are spread loosely on the ground to dry in the sun.
Dried fiber at appropriate temperature, will be combed once called “One-Tie”, if it combed twice it will become “Two-Tie”. This process is carrying out though humans manually. Thereafter the fibers are rolled and tied into loose bundles for storage or shipment.
Note:After the sun dry Ceylon Brush Tech uses: Methyl bromide fumigation.
