Home · How it's made

From husk to pallet, one stage at a time.

Four products come off one raw material. What separates them is where they leave the line — and every stage carries a number we measure rather than an adjective we claim.

Process 01

Cocopeat blocks

Nine stages. The three that decide whether the product is export grade are washing, drying and pressing — conductivity, moisture, and block weight.

Block line

Husk in · 5 kg block out
Cocopeat block production flow Nine stages: husk intake, decorticator, trommel screen, three-stage wash to EC 0.5, screw press to 50 percent moisture, dryer to 15 percent, grading screen, hydraulic block press, then wrap, label and palletise. 010203 040506 070809 Huskintake Decorticator Trommelscreen 3-stagewash Screwpress Dryer Gradingscreen Blockpress Wrap &palletise EC ≤ 0.5mS/cm 14–18%moisture 5 kg ±30 g5:1 ratio MATERIAL STATE Raw husk Fibre + pith Washed pith · ~80% wet Dry graded pith Block
Stage 04 · Washing Three tanks run counter-current, so the cleanest water meets the cleanest pith last. An inline probe reads conductivity at the third outlet and the batch does not advance until it sits at or below 0.5 mS/cm.
Stage 06 · Drying Temperature is held under 50 °C. Push it higher and you dry faster but scorch colour and collapse the pore structure that makes coir hold water in the first place.
Stage 08 · Pressing A 5:1 compression ratio. A 5 kg block rehydrates to roughly 70–75 litres of usable substrate, which is what makes the freight economics work over sending loose pith.
Stage 09 · Traceability Batch number, conductivity, pH, moisture and date print onto the label with a QR code before the block goes onto the pallet.

Process 02

Grow bags

Identical up to grading. The bag line takes the medium fraction rather than the fine, because roots need air as much as they need water.

Grow bag line

Shares stages 01–07 with the block line
Grow bag production flow Shared upstream stages produce graded pith; the bag line then forms the HDPE sleeve, fills to weight, perforates for drainage, heat seals, weight-checks, labels with a QR code and palletises. 01–07 Shared upstream wash · dry · grade see process 01 080910 11121314 Bag formingHDPE sleeve Volumetricfill Perforation Heat seal Weightcheck Label+ QR Palletise UV-stabilisedHDPE film 20–40 holes3–5 mm ±200 gper bag MATERIAL STATE Graded medium-fraction pith Filled sleeve Sealed, labelled bag
Why the medium fraction Fine pith holds water beautifully and drains badly. In a bag that sits under drip irrigation for a full season, the medium grade keeps air-filled porosity where roots need it.
Stage 10 · Perforation Twenty to forty holes per bag at 3–5 mm. Too few and the bag waterlogs; too many and it dries out between irrigation cycles.
Stage 12 · Weight check Every bag is weighed, not sampled. A pallet where bags vary by a kilo gives a grower uneven plants down the row.
Formats Slab, open-top and custom sleeve dimensions. Fill weight from 8 kg to 30 kg depending on crop and container spacing.

Process 03

Coir fibre

The fibre leaves the line early — at the trommel, before anything gets washed. It is the structural half of the husk, and it has its own set of buyers.

Fibre line

Diverges at stage 03
Coir fibre production flow Husk intake, decorticator, trommel separation, de-dusting, air drying to below 18 percent moisture, hydraulic baling and strapping, then weighing and marking for despatch. 010203 040506 Husk intake Decorticator Fibre / pithseparation De-dusting+ air drying Hydraulicbaling Weigh, mark& despatch ~30% of huskweight is fibre < 18%moisture 1 × 0.5 × 0.5 m90–120 kg bale MATERIAL STATE Raw husk Loose fibre, dusty Clean dry fibre Strapped bale
Two grades off one drum Long fibre goes to rope, matting, brush and geotextile. Shorter mixed bristle goes into erosion-control blankets and mattress filling.
De-dusting matters Fibre carrying residual pith dust loses tensile grip and stains anything it is spun with. It gets shaken clean before it is ever baled.
Fibre as fuel Fibre we do not sell burns in the biomass furnace that heats the dryer. The by-product of the by-product powers the line.
Bale density Baled to a consistent density so a 20-foot container loads to a predictable tonnage rather than cubing out half empty.

Process 04

Coco compost

The slowest product on the site. Coir pith is stubbornly high in carbon, so it has to be composted properly rather than simply aged and rebranded.

Compost yard

8–12 weeks, windrow method
Coco compost production flow Six stages over eight to twelve weeks: coir pith is blended with nitrogen-rich farm residue, inoculated with fungal culture, formed into windrows, turned on a cycle while core temperature is monitored, matured until stable, then screened and bagged. 010203 040506 Blend pith +farm residue Inoculatefungal culture Windrowforming Turning cycle+ monitoring Maturation Screen& bag C:N broughttoward 30:1 55–65 °C coreturned weekly 8–12 weeksto stability MATERIAL STATE Raw pith, C:N ~100:1 Active thermophilic pile Stable, screened compost
Why raw pith is not compost Coir pith arrives near 100:1 carbon to nitrogen. Dug in at that ratio it robs nitrogen from the soil instead of adding it. Blending brings the ratio down before composting starts.
Stage 04 · The turning cycle Core temperature is logged. Holding 55–65 °C is what kills weed seed and pathogens; turning keeps the pile aerobic so it composts rather than sours.
Stage 05 · Knowing when it's done Stability is tested, not guessed at. Compost that still respires strongly will keep working in the bag and can damage seedlings.
Nothing synthetic added Nitrogen comes from farm residue and coconut-processing waste. No mineral fertiliser is blended in to force the ratio.

Quality control

Five readings on every batch.

A certificate of analysis travels with each consignment. These are the figures on it, and they come off instruments in our own lab rather than a supplier's word.

Conductivity (EC) pH Moisture Particle size distribution Water-holding capacity
Where each quality reading is taken Conductivity and pH are read at the wash outlet, moisture at the dryer outlet, particle size at the grading screen, and water-holding capacity on the finished product. SAMPLE POINT MEASURED Wash tank 3 outlet Dryer outlet Grading screen Finished block / bag Retained sample EC · pH Moisture % Particle size WHC · weight Held 12 months

Want a sample before you commit?

We send a sample pack with the certificate of analysis for the batch it came from, so you can test against your own water and your own crop.

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