At Grimeford Mill, we're proud to shine a spotlight on coir matting - an essential but occasionally overlooked feature at the doorsteps of homes and businesses. Whilst doormats may appear simple at first glance, coir matting reveals a fascinating journey from natural fibre to the durable and attractive mats adorning our entrances.

Coir matting is a robust and eco-friendly product that is made from the fibrous husks of coconuts. This natural resource is not only durable and strong but also has a long history of use in various applications, including doormats, sacking, and upholstery stuffing. These fibres have played an important role since the 11th century, valued not just for their utility as doormats but also for their ecological advantages, being organic and fully compostable.  At Grimeford Mill, we take pride in offering high-quality coir matting that is designed to last, available in a range of colours and sizes to suit your requirements.

Manufacturing Process

The creation of coir mats is a process that marries age-old practices with contemporary advances. The transformation of fibres into yarn and then into mats involves several steps, each crucial for achieving the highest quality of coir matting:

1. De-husking and Preparation: the journey of coir matting begins with the harvesting of coconut husks. This process, which is carried out with care to ensure the sustainability of coconut palms, separates the husk from the coconut's edible part using a machete.

2. Soaking: the husks are then submerged in water to foster bacterial growth, which helps to break down the husk and soften the fibres. This soaking process, traditionally in tidal waters, is an important step to soften the fibres and aid separation.

3. Sorting and Bundling: the fibres are then extracted and dried to prevent decay and maintain the integrity of the matting. The coir fibres are then loosened and separated based on length. This selection process ensures that only fibres of optimal strength and durability are used for matting.

4. Weaving the Mats: the selected fibres are spun into yarn, which can be done manually or mechanically. The yarn is then woven or tufted to produce mats of varying densities and designs.

5. Customisation: the final touch involves dyeing the fibres, either with natural or synthetic dyes, to create mats that not only serve a functional purpose but also enhance the aesthetics of any space. This process is carefully controlled to ensure the durability of colours and to minimise environmental impact.

Coir matting is known for its environmental benefits. As a natural and renewable resource, coir has a minimal carbon footprint. Its production process, predominantly reliant on natural processes and manual labour, further reduces environmental impact. At the end of its life, coir can be composted, returning valuable nutrients to the soil and completing its ecological cycle. It is also utilised in gardening as a peat compost alternative, offering a sustainable and environmentally friendly option.

Grimeford Mill is committed to providing high-quality coir matting solutions that blend durability, style, and functionality. Our coir mats are PVC-backed and available in a variety of colours, thicknesses, and sizes, including made-to-measure options to perfectly fit within your space. For more detailed information, please visit our coir matting page or contact us today on 01772 330051, and a member of our team will be happy to help!