01 · Spinning
Coir fibre is spun into yarn to the specification required for the selected construction.
02 · Tufting
Spun coir yarn is tufted on powered loom lines to form the mat pile.
03 · Shearing & Trimming
Shearing and precision trimming bring every mat to final pile height and clean edges.
04 · Paint Manufacturing
Our in-house paint plant supplies the print operation to approved programme requirements.
05 · Pantone Mixing
Colours are matched to approved Pantone references and buyer artwork before production printing.
06 · Printing
Approved designs are printed onto the prepared mat surface to programme specifications.
07 · Drying
Printed mats are dried before back coating and final handling.
08 · Back Coating
PVC, latex or rubber backing is applied according to the approved construction.
09 · Labelling & Packing
Retail-ready packing, barcoding and labelling are completed in the on-campus packing unit.
10 · Dispatch
Finished stock is staged across two warehouses for organised, on-time container dispatch.
