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Coir Mats—An Eco-Friendly Sustainable Production Process!

Let’s be honest—in today’s day and age you would be hard pressed to find a product that hasn’t undergone some pretty extensive production processes. Even packaging is excessive with finished products having to be shipped to different locations just to be shrink-wrapped, boxed, tapped up, and then shipped out again! I am certain we’ve all seen it—products that are overly packaged with a list of ingredients or materials that is a mile long. But there are some producers who have stepped back and taken a closer look at the consequences of their ecological obliviousness. Cocoa mats are made from an organic material (derived from coconuts) that has little to no negative impact on the environment. A natural doormat is put together in traditional ways that rely mostly on human power instead of electricity. So if you want to support an ecologically responsible product that isn’t just made with organic material but which is also put together with nearly no pollution—then a beautiful woven doormat is the right choice for you!

Since natural coir matting is available in a range of styles—from coir and rubber backed mats to fully coco fiber scrapers, the assembly of these products can vary. But if you’re interested in learning more, here is a step-by-step guide to the production of 100% cocoa mats or otherwise known as scrapers.

  1. Coir Length
    After being extracted, coir fiber is sorted and bundled based on the length of the fibers. This is important because different sized fibers are better suited for different applications—shorter fibers are tough and used to make bristled rods. Longer fibers are perfectly suited to be woven into cocoa mats.
  1. Bristled Rods
    With cocoa mats and scrapers, bristled rods are an essential part of the structure because they make the product strong enough to support the weight of a human. These rods are made by feeding a bundle of the previously made fiber through a metal rod that is then quickly spun using a hand-powered device. The end result is a full and durable bristled rod of coir.
  1. Trimming

Although the fibers have previously been divided by length, the spun bristles are trimmed so that they are all the same length. This is done by hand on a lower energy roller. This will fortify and beautify the natural coir matting, ensuring that all the bristle rods are uniform.

  1. The Frame

Skilled workers then weave together metal wire to make the frame of cocoa mats. This is also done entirely by hand, ensuring the quality of the product in a way that a huge industrial machine could never replicate.

  1. Putting it Together
    Coir rods are trimmed to different lengths. These rods, of varying lengths, will be inserted into the wire frame to make various patterns and shapes—like stars, stripes, and even penguins! Although this doesn’t constitute a woven doormat, the stringing of the rods through the wire frames does take a certain degree of weaving experience. Longer rods go around the perimeter of the mat, while shorter ones are hammered into place in order to make the desired pattern or design.
  1. Beautification
    Once assembled, although the color of a natural doormat is already quite beautiful, it may end up being sent to another warehouse where it will be airbrushed with a creative design, picture, or message. Each mat is carefully hand painted with the use of stencils.
The doormat in brown & tan color combination design around the border at front door
Eco-Friendly Coir Mat with a picture of garden fence & plant

If you’re looking to reduce your carbon footprint but aren’t willing to skimp on quality and durability (which you shouldn’t have to!), then cocoa mats are the perfect choice for your entryways! Small-scale natural coir matting production is a cottage industry that is staying in competition against bigger factory-based companies due to the high quality of their work. A natural doormat is going to compliment your home and comes available in a number of designs and shapes—from half-moons, ovals, and even the curved edges that mimic the petals of a flower. And don’t forget, coconut fiber is so strong that it can easily stand up to moisture, snow, dirt and grime making it the perfect ally in your battle to keep your home clean. Available as scraper, bristled, or woven cocoa mats the functionality of coir is going to make it easy to apply its use to your home.

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