Work in Cottage Industry
Brain Mat (Coir Mat) is designed in traditional attention with the coconut husk to benefit every user to improve individual Health.
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.
On the other hand, the climber uses a bamboo pole with a knife attached to the end to cut selected coconuts on the treetop vegetation and, and he can harvest 250 trees per 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 the steel tip spikey instrument to split the husk. The 2,000 coconut husks will get split, and peel off manually by the skilled worker in a day, whereas the machines can finish the same work in an hour.
Ret & Defiber
Retting the husks of the coconut is a curing process and is kept in an open environment to do natural microbes observation. The action taken will decompose the pulp of the husk to separate the coir fibre.
There are two ways of retting, freshwater retting and saltwater retting with the coconut husk to produce brown and white coir. Now techniques using machines to process the ripe husk by crushing are retted after 7-10days.
In the traditional way of retting, the pulp is beaten up by the workers with the wooden hammer to segregate the fibres from the pith and the outer layer. The separation process is then completed only after washing the remaining from the de-fibre process. Later the combing process through it by hand or tumbling in a sieve or drum. The clean and neat fibres are spread on the ground to get dry in the sun.
Bristle fibre Manual Twist
Bristle fibres are rolled and tied into loose bundles for storage or the fibres are combed using manual tools or machines into a thick yarn later re-spun into a fine yarn.
Fibre Bundle
The twisted yarns transform into twine, which in turn braided into ropes later into bundles.
Yarn into Mats
The fibres bundles are separated to do mat rolls by hand twist or machine twist, later cut into the 8-shaped Walking Mat finally sprayed with latex rubber and dried as required for the extra grip.
