Retting the husks of the coconut is a curing process, kept in an open environment to get natural microbe reaction.
In the traditional way the pulp is beaten by the workers with a wooden hammer to segregate the fibres from the pith and the outer layer. The separated fibres are combed through by hand or tumbling in a sieve or drum. The clean and neat fibres are spread on the ground to dry in the sun.
Work in Cottage Industry
Brain Mat (Coir Mat) is designed with traditional coconut husk. The benefits are to small vendors, individuals and local cottage industry
Harvest and husk
Coconuts collected from the ground will be ripe and fall by themselves from the trees. Coconuts stick to the 40-100 ft (12-30m) tall trees and are harvested by human climbers. The climber picks the fruit by hand, and he can harvest fruits from about 20 trees in a single day.
Ripe coconuts are ready to husk, and the unripe will be spread in the ground for a month to get dry. The coconut fruit will be removed from the shell using a steel tip spikey instrument to split the husk. The coconut husks will get split, and peeled off manually by the skilled worker.
Ret & Defiber
Bristle fibre Manual Twist
Bristle fibres are rolled and tied into loose bundles for process into a thick yarn using manual tools or machines.
Fibre Bundle
The twisted yarns transform into twine, which is braided into ropes.
Ropes into Mats
The ropes are woven manually into mat rolls and later cut into the 8-shaped Infinity Walking Mat.
