How Footluze Coco Mats Are Made

Origin & Production of Coco Mats

Coir Fibre From CoconutsAll of Footluze's Coco Mats are constructed from genuine coco fibers, also called coir fibers. Coir (pronounced "coy-er") is a popular choice for entry mats and rugs due to its extreme durability and toughness in high-traffic areas. The thick, short fibers are quick-drying and weather-resistant, absorbing moisture without mildew. Naturally resistant to rain and sea water, these rugs are perfect by the pool, in your entryway, or leading to your outdoor room.

Coir comes from the thick middle layer of coconuts (called mesocarp). The fibers are 100% organic and biodegradable. The fiber is impervious to rain and seawater, which is nature's way of protecting the coconut seed. Because of these strong, durable coir fibers, a coconut can float in the sea for long periods of time and the fruit of the coconut will still be fresh. Harvesting of coir is based in rural India and Sri Lanka. The state of Kerala, also known as the " land of coconuts", is the largest producer of coir in India, yielding more than 75% of the total production. Other producers include West Africa, Central America, and South America.

How Coco Mats are Made

Coir Fibre Cocount Mat ProductionThe preparation of coir fibers is a painstaking process. Younger coconuts (rumata) are preferred for harvesting coir, as unripe fruits contain the longest, strongest fibers. It takes approximately 100 coconuts to produce 18 pounds of fibers.  The following steps outline the process by which coco mats are made.

  1. Husks (called purus) are separated from coconut shells and soaked in briny lagoon water for periods of up to 10 months, a process called retting. Usually, a shallow hole is scooped out at the bottom of knee-deep water, where the husk sections (called akanga) are buried beneath sand. The purpose of retting is to separate the fiber from the corky material (called pith).
  2. The husks are beaten with wooden mallets to loosen the pale yellow fibers and convert them into a silky, fine material. (Fibers range from 4-12 inches long.) The beating process is called ta ti tukaha.
  3. The beaten fibers are dried in the sun, and are then either spun by hand or on spinning wheels called RATTS. The spinning process transforms the fibers into a smooth, yarn-like material.
  4. Spun coir is often dyed to a desired shade. (Its natural color ranges from golden- to reddish-brown.)
  5. The dyed yarn is hand-woven into mats and backed with nibbed rubber to keep them in place.

If you have any questions about Coco Mats or any of our other products, please contact us.