QUALITY CONTROL

Introduction

Coir fibre is obtained from the Outer layer of the fruit of Coconut tree (Cocos Nucifera L). This outer layer is called the coconut husk. The husk (exocarp) of the coconut consists of a smooth waterproof outer skin (epicarp) and fibrous zone (mesocarp). The mesocarp comprises of strands of fibro vascular bundles of coir embedded in a non fibrous paranchymatous "corky" connective tissue usually referred to as pith; which ultimately becomes coir dust.

Chemically coir fibre is composed of a highly lignified form of cellulose (cellulose lignin complex), which accounts for its colour, harshness and relative brittleness in comparison with pure cellulose fibre. The bulk of the ground tissue of the husk, on the other hand, is made up of pectin and hemicelluloses (Nathaniel 1960). i.e. pectin and hemi cellulose act as a spongy binding material that bind the large fibre cells together to make up the husk. Coconut coir is in great demand unaccounted of natural resilience, durability, resistance to dampness and other properties. Grading of coir is based on its fibre length, colour, resilience and general cleanliness in relation to the quantity of pith present.

All coir fibre falls into two distinctly different categories, white (golden yellow) and brown coir. The differences are due to the conditions of husk used, the method of extraction, the physical properties as well as in the uses. Coir obtained from immature green coconut is generally known as white (golden yellow) fibre and is finer than the brown fibre obtained from matured and seasoned coconuts, which has lost their green colour (>12 months). Both types of fibre are widely used and each has its own unique distinct type of application.

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.