How Do You Make Coir Step-by-Step?

Coir is made by first harvesting the coconuts and removing the husks, followed by curing the husks. And in the last few steps, the cured husks are milled, and the fibers are separated. It is clear that the process of making coir involves several steps. Let us dive into each one in detail. The very first step in producing coir is harvesting the coconuts that grow in tropical regions of the world. Coconut harvesting is still done by humans in countries like India and Sri Lanka. Harvesters usually climb the trees, which can grow up to 100 feet, and cut the coconuts from the treetops using knives specifically designed for the purpose. If a tree is relatively short, harvesters may use knives attached to the end of bamboo poles to cut down its coconuts. The harvested coconuts must be de-husked before the extraction process begins as the fibers are found inside the coconut. The de-husking process removes the husk from the coconut seed and is done manually by human workers using methods that have been in use for hundreds of years. Human labor is still the most efficient way to de-husk coconuts. While there have been efforts to build mechanical dehuskers, these have largely been unsuccessful at replacing human labor, according to research published in the Journal of Food Engineering.

Once the husks are removed, they are cured using a process called “retting.” Retting is necessary to separate the coir fibers from the pith to make different products like brushes and seed starters. The retting process depends on the maturity of the coconut. If the coconut is mature, the husks are cured in fresh water for three days. Workers typically soak the husks in concrete tanks filled with river water. In countries like India and Sri Lanka, you can still see traditional methods of freshwater retting where the coconut husks are buried along riverbanks. Some small-scale producers may submerge the husks in rivers using nets made from coconut fibers! Unripe coconut husks are cured in seawater or briny water in a prolonged process that can take up to ten months. Just like freshwater retting, saltwater retting involves concrete tanks. Alternatively, coastal-area producers may suspend the husks on briny rivers near the ocean, so that when the tides come, the husks are rinsed in seawater. The retting process decomposes the coconut husks, allowing the fibers to be separated from the coir pith. Once the curing process is complete, the resulting pulp is sent for milling.