Manufacturing
From husk to certified substrate.
Six controlled production stages turn raw coconut husks into export-grade buffered coir substrates. Every stage is documented. Every batch is lab-tested before it leaves Tamil Nadu.
6
Production stages
3×
Wash cycles
In-house
QC laboratory
< 2%
Waste to landfill
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01
Coconut husk sourcing
Husks sourced from certified Tamil Nadu farms within a 150 km radius of our facility. Supplier farms operate under Good Agricultural Practice and are audited annually. Traceability data is logged at intake.
02
Fibre separation & screening
Husks are fed through decorticating machines that separate long coir fibre from the fine pith. Pith is screened into substrate-grade and non-substrate fractions. Non-substrate material is diverted to fuel log production.
03
Triple-wash cycle
Substrate-grade pith enters a three-stage washing cycle using fresh water. Each stage reduces soluble salt (EC) content. Post-wash EC is measured and batches above 0.6 mS/cm are returned for additional washing.
04
Buffering
Washed pith is buffered to displace naturally occurring sodium and potassium, ensuring the substrate is ready for immediate use without stripping your nutrient solution.
05
QC lab testing
Every production batch is tested in our in-house lab before compression. Parameters measured: EC (1:1.5 extract), pH, moisture content, bulk density, water holding capacity, and air-filled porosity. Results are logged to the batch record.
06
Compression & export packing
Approved batches are compressed into blocks, briquettes, or precision-filled grow bags. Container loading is supervised and weighed. COA and full documentation set are prepared before the container is sealed.
See the full quality standard
Quality starts at the source.
From farm intake to final COA — every step documented. Request our process documentation or arrange a virtual facility tour.