Once the coir of the coconut has been husked, separated, and sorted by length, the coir doormat making process can begin. The true quality of coir mats shines through due to their hand-crafted quality, and the high levels of skill and dedication that go into making each and every one. First, bundled coir fibers of equal length are wound together through a metal rod and quickly spun. The purpose of this is to intertwine the fibers, helping to give them the dense, durable composition that makes coir doormats so sought. This spinning action creates a full, bristled rod of coir. These rods are then grinded along a simple, spinning shaving device to give them an equal, consistent length. This consistency is partially what makes every coir mat reliable and dependable.
Next, skilled workers weave together metal wiring to create the frame for each doormat. This framing provides the sturdy base upon which the fibers are affixed, and the coir mat created. These frames are made solely by hand or with small tools. Long, bundles of coir are then placed along the perimeter of the metal frame, while smaller coir bundles are inserted throughout. These interior coir bundles are arranged by hand as well (with the help of small mallets that is).The interior coir can further be arranged in visually pleasing, symmetrical patterns to give these doormats the rustic aesthetic they are prized for.
Some coir mats are then taken to separate facilities where they are airbrushed with simple designs. Others are simply brought “as is” to storage facilities, where they patiently await shipment to your home or office!
Every part of the coir door mat creation process is undergone with dedication and care. From the coconut husking to the formation of the coir mats themselves, these doormats are made with a level of pride and skill that is hard to find almost anywhere else!
At Coir Mat.com, we supply only the highest quality coir door mats, decorative mats, and boot scrapers.