Proceedings of the Symposium on Natural Fibres 63

Coir fibre in Asia

Romulo Arancon, APCC, Jakarta

OUTLINE

I. Unique Properties of II. Coir Products and Uses III. Coir Fibre and Coir Pith Resources IV. World Coir Export and Prices V. Emerging Applications of Coir Products VI. Challenges in the Coir Industry Towards Reducing Poverty and Promoting Employment and Income

I. Coir, the product extracted from husk has unique properties compared II. COIR PRODUCTS AND USES to other natural fibres in several ways: It is the thickest and most resistant of all Coir’s properties have commercial natural fibres. made it the fibre of choice Its cellular structure makes it more elastic than for several uses: other natural fibres. The cell – walls of coir fibre and pith contain General purpose and more than any other commercially relevant natural fibre. in producing countries, Lignin is a natural polymer, which adds strength where these products are a and elasticity to the based fibre walls. common sight in roadside Since lignin resists bio-degradation, a high lignin stalls. content also imparts longevity to outdoor applications.

II. COIR PRODUCTS AND USES II. COIR PRODUCTS AND USES

 Almost indestructible, scrubby and Brooms and Brushes : increasingly stylish doormats and from hand brushes to the a wide range of designs of double metal wire twisted tawashi rugs. brushes used in the kitchen. No other natural fibre makes better This sector is another area doormats yet synthetics always where the stiffness and loom as a competitor. durability of coir make it a Manufactures try to maintain a role natural choice with limited for coir by offering softer rugs made competition, even by from blends of coir and other synthetics. tropical fibres, such as and , in a range of designs.

II. COIR PRODUCTS AND USES II. COIR PRODUCTS AND USES

 , upholstery, car seats, often as non-  Car seat covers are woven sprayed with still found in several naturel latex (rubberized high-end European car coir). models. Rubberized coir is also making In and China, inroads as durable particularly the demand for . more “sleeping comfort” has reignited the market. 64 Proceedings of the Symposium on Natural Fibres

GEOTEXTILES AND ORGANIC II. COIR PRODUCTS AND USES PLANTER POTS Coir Waste and Dust (Pith) Technological advances in bioengineering and While extracting coir fibre, the urgent need to rehabilitate degraded lands, slopes short fibre (2mm or less) and dust led to development of new applications of (pith) are left behind as a waste coir. product. Coir nets/, coco rolls or Coir dust or coconut is a biologs are used for environmental protection – good planting medium with erosion control (desertification in China). excellent water holding capacity These products are preferred due to strength, (up to 8 to 9 times its dry weight). ecological qualities and biodegradability.

COIR GEOTEXTILES (COIR BHOOVASTRA) COIR GEOTEXTILES (COIR BHOOVASTRA)

Coir netting Cocolog Coir needled

Erosion control blanket

COIR GEOTEXTILES (COIR BHOOVASTRA) COIR GEOTEXTILES (COIR BHOOVASTRA)

Prevent soil erosion in the slopes / embankments of road.

Railway embankment protection

COIR GEOTEXTILES (COIR BHOOVASTRA) COIR GEOTEXTILES (COIR BHOOVASTRA)

River bank protection Reservoir bank protection Mud wall reinforcement Stream bank protection Proceedings of the Symposium on Natural Fibres 65

GARDEN ARTICLES FROM COIR GARDEN ARTICLES FROM COIR

Coconut planter pots as soil-less potting medium from coir dust which can hold water at least twice its own weight.

Coco pots Coir Hanging Basket Creeper poles Coir Basket

GARDEN ARTICLES FROM COIR C O C O L A W N TM

Cocolawn, a ready to use lush green natural lawn made from coir geo , coir non woven felt, coir pith and composted coir pith on which the lawn grasses could be planted.

Coir Pith Bricks

BINDER – LESS BOARD FROM SOFTENED COIR PRODUCTS COCONUT HUSK (ECOCOBOARD) Cushions / pillows / mats were developed PCA – ATO – DLO – CFC – FPRDI developed the from softened coir fibre which has supple feel. production process of fiberboard using natural lignin The softened fibre do not induce skin content of coconut husk. sensitisation in guinea pigs and it is non-irritant to the mucous membrane in rabbits.

Can be used as construction materials, molded 3D Cushion Seat cushions for Softened coir furniture parts & accessories & as packaging material school children pillow for machineries.

PRODUCT DIVERSIFICATION COIR FIBRE

Fibre Brushes Bristle Husk Pith Fibre Bricks Floor Omatt Covers Mix Fibre Fibre Mattress Bales Fibre Twine Mattress Fibre Bales Rubberized Twisted Coir Fibre Bio Composites Engineering For Mattresses 66 Proceedings of the Symposium on Natural Fibres

COIR BRISTLE FIBRE COIR BRISTLE FIBRE

Boot Wiper Brushes

Bristle Fibre For Carpets Bristle Fibre For Brushes

COIR TWISTED FIBRE COIR TWINE

Black Dyed Coils Coir Twine in Hanks For Hop Industry

For Car Seat Twisted Fibre Natural Coils Coir Twine in Roll For Oyster Cultivation

COIR TWINE RUBBERIZED COIR/COIR POTS

Coco Pots for Commercial Carpet Twine For Floor Coverings Gardening

Rubberized Coir

Garden Twine For Liners for Hanging Baskets

WOVEN GEOTEXTILES STITCHED BLANKETS

For Erosion Control For Soil Erosion Control

Geotextile Roll Stitched Blanket Roll

For River Bank Protection Proceedings of the Symposium on Natural Fibres 67

USES OF COCOPEAT & HUSK COIR FIBRE PITH SUBSTRATE Growing media in the Green House Industry Sold in the Garden Centers as potting As a Growing Media soil Alternative to Peat moss in Soil less cultivation Used in landscapes

III. GLOBAL COCONUT PRODUCTION AND Table 1. Global Coconut Production and Potential POTENTIAL AVAILABILITY OF COIR FIBRE Availability of Coir Fibre and Coir Pith at 50% Available Husks AND COIR PITH Available Husks At 50% availability of husks Total Nut Production Fibre Coir pith (million) is grown in more than 93 (million tonnes) World 61,165 3.67 8.5 countries in the world, in an area of Asia – Pacific 52,936 3.17 7.4 about 12.05 million ha and produce APCC Countries 50,577 3.03 7.1 Africa 2,187 0.13 0.30 61,165 million nuts. American 6,047 0.36 0.84

The Asia and Pacific countries Assumption Husk : 400 gram

alone produce 52,936 million nuts. Fibre : 120 gram (30%)

Coir dusk & shorts : 280 gram (70%)

Table 2. Coconut Production in Asian and Pacific Countries, Potential Availability of Fiber (at 50% of Available Husk)

At 50% Available Nuts for Husking While 93 countries are growing Production of Nuts Country (Million) Fiber Coir Pith (Thousand Ton) (Thousand Ton) coconuts, India and are the 1. F.S. Micronesia 40 2.4 5.6 2. 150 9.0 21.0 major producers of coir and coir 3. India 12,160 729.6 1,702.4 4. Indonesia 19,537 1,172.2 2,735.2 products. 5. Kiribati 53 3.2 7.4 6. Malaysia 400 24.0 56.0 7. Marshall Islands 41 2.5 5.7 The production of coconut in major 8. Papua New Guinea 712 42.7 99.7 9. 12,456 747.4 1,743.8 10. Samoa 190 11.4 26.6 Asian countries and the potential 11. Solomon Islands 110 6.6 15.4 12. Sri Lanka 2,591 155.5 362.7 availability of coir fibre and pith are 13. Thailand 1,199 71.9 167.9 14. Vanuatu 258 15.5 36.1 given in table 2. 15. Vietnam 680 40.8 95.2 Total 50,577 3,034.7 7,070.8

Table 3. Production of Coir Fiber IV. WORLD COIR EXPORT (thousand Tones) AND PRICES Brown White Fibers Figure 1. World Coir Export (MT) Thousands MT (5-year average) 400 130 Export 350 120 INDIA 300 110 250 100 250 200 150 90 200 100 80 50 0 70 150 2001 2002 2003 2003 2004 2005 2006 2007 2002 2003 2004 2005 2006 2007 2008 100 India Sri Lanka Thailand Vietnam Other 50

0 1960-64 1965-69 1970-74 1975-79 1980-84 1985-89 1990-94 1995-99 2000-'04 2005-'07 68 Proceedings of the Symposium on Natural Fibres

Figure 2. India Export of Coir Figure 3. Sri Lanka Export of Coir Products, 2003 – 2007 Figure 3. SriProducts, Lanka Export 2003 of Coir– 2007 Products, 2003 - Thousands MT Thousands MT

80 60 50 60 40 40 30 20 20 10 0 0 '03 '04 '05 '06 '07 '03 '04 '05 '06 '07 Rope Rubberized Rug-carpet Others Mattings Yarn Mats Husk-chip Twine Yarn Bristle Mattress Twisted

Figure 4. India Export Prices of Coir Figure 5. Sri Lanka Export Prices of Products, 1983 - 2007 Coir Products, 1983-2007

In US $/MT In US $/MT Yarn Matting Mats Rope CNO Mattress Bristle Yarn Twine

2000 1200 1000 1500 800 1000 600 400 500 200 0 0 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99'00'01'02'03'04'05'06'07 '83'84'85'86'87'88'89'90'91'92'93'94'95'96'97'98'99'00'01'02'03'04'05'06'07

Figure 6. Main Importers of Coir Yarn, Figure 7. Main Importers of Coir Fiber, 1990 – 2007 1990 – 2007

Thousands MT (5-year average) Thousands MT (5-year average)

90/95 95/99 00/04 05/07 00/04 95/99 90/94 6 50 45 05/07 40 35 4 30 25 20 2 15 10 5 0 0 Belgium France Germ. Italy USA Germ. Nether. U.K. Spain China Japan S. Africa

V. EMERGING APPLICATIONS OF COIR V. EMERGING APPLICATIONS OF COIR AND COIR PITH AND COIR PITH  Natural fibres as reinforcements in Coir fibre products for soil industrial products have made considerable heedway in the strengthening as reinforcement in automotive interiors especially in tropical soils has been shown to be Europe for reducing cost and effective. weight. In horticulture sector, natural fibre can  Several European firms are testing play a vital role (with reasonable whether coir can play a role in a strength and disposability in growing automotive market for transporting flowers, vegetables, , “bio composites”, or as in home construction. etc. pots for planting). Proceedings of the Symposium on Natural Fibres 69

V. EMERGING APPLICATIONS OF COIR V. EMERGING APPLICATIONS OF COIR AND COIR PITH AND COIR PITH

 In the Netherlands about 2 million pots of Use of coconut fibres in asphalt and plants are produced consuming about unpaved rural roads can be tested 30,000 tonnes of synthetic plastics. Bio- on pilot scale for bulk utility. degradable pots using natural fibres can Rubberized coir used to be the be produced replacing synthetic plastics. material of choice for car seats, but largely lost out to competition from synthetic foams. Yet, the remaining use of coir in several high-end European car models is an example of how products can stay competitive and possibly regain ground.

V. EMERGING APPLICATIONS OF COIR V. EMERGING APPLICATIONS OF COIR AND COIR PITH AND COIR PITH

Geotextiles – made out of coir Low cost wall panels from Blast fibre is an important ecofriendly Furnace Slag Cement using coir product which is gaining fibres have been developed in market in Europe, Asian and US Brazil as a low cost countries as erosion control environmental sensitive blankets, nets for slope technology. This technology is protection, mulch blankets, available in the Institute de Pesquisas Technologie basket , ‘coir bio roll’, do Estado de Sao Paulo S.A., Brazil. roof greening , grow sticks, High-tech products of industrial textiles is also coco logs, grow media as well possible and needs to be exploited by importing as skeffed coir for river bank / coir fibre. canal bank support.

V. EMERGING APPLICATIONS OF COIR VI. CHALLENGES IN THE COIR INDUSTRY TOWARDS REDUCING POVERTY AND PROMOTING AND COIR PITH EMPLOYMENT AND INCOME

Ecocoboards have been 1. For about 150 years, the coir industry is still practicing succesfully produced traditional ways and many from coconut husk and do not have facilities for have a wide scope for workers and is not commercialization for hygienic. use in mass housing. Improving the working conditions will help to increase the efficiency of labor. Especially the large number of women who are involved in traditional fiber extraction.

VI. CHALLENGES IN THE COIR INDUSTRY TOWARDS VI. CHALLENGES IN THE COIR INDUSTRY TOWARDS REDUCING POVERTY AND PROMOTING REDUCING POVERTY AND PROMOTING EMPLOYMENT AND INCOME EMPLOYMENT AND INCOME 3. Improve efficiencies of production 2. Integrated farm level processing and processing should include as a community/cooperative improved agronomic practices to approach will facilitate greater increase coconut production and availability of husk in a particular ensure food security. place rather than what individual An increase in the productivity will smallholders are doing in a increase the raw material scattered way. availability. Besides providing large quantity of husk, this will also provide additional employment and income to Improving the processing efficiency the farming family. (Aggregator or consolidator’s and quality have remained to be a concept) challenge. 70 Proceedings of the Symposium on Natural Fibres

VI. CHALLENGES IN THE COIR INDUSTRY TOWARDS VI. CHALLENGES IN THE COIR INDUSTRY TOWARDS REDUCING POVERTY AND PROMOTING REDUCING POVERTY AND PROMOTING EMPLOYMENT AND INCOME EMPLOYMENT AND INCOME 5. Use of coconut husk, for 4. New and improved products making grow bags using cut should be developed fibre, husk chips and coir especially in applications where natural fibres have pith has potential market in advantage over synthetics. horticulture and for growing vegetables and ornamental Among these are plants, flower plants, etc. geotextiles, carpeting, wall However, the quality covering, wire rope cores, composites, ecocoboards standards for these products and packaging materials. have to the maintained (salt content).

VI. CHALLENGES IN THE COIR INDUSTRY TOWARDS VI. CHALLENGES IN THE COIR INDUSTRY TOWARDS REDUCING POVERTY AND PROMOTING REDUCING POVERTY AND PROMOTING EMPLOYMENT AND INCOME EMPLOYMENT AND INCOME

7. Since many of the developing New Technologies for 6. Strengthening the countries growing coconuts are Fibre Extracting institutional capabilities not utilizing coconut husk to produce value added products, of coconut growing providing such facilities can go countries so as to along way to provide enable them to employment, increase the undertake their own income of coconut farmers and Decorticator reduce poverty. Capacity : 3,2 tons fibre output / 8 hrs research and development activities on husk utilization. There is a need to develop institutional capabilities or capacity building.

VI. CHALLENGES IN THE COIR INDUSTRY TOWARDS VI. CHALLENGES IN THE COIR INDUSTRY TOWARDS REDUCING POVERTY AND PROMOTING REDUCING POVERTY AND PROMOTING EMPLOYMENT AND INCOME EMPLOYMENT AND INCOME

A good example is the This facility will also New Technologies for Floor Carpet Manufacturing CFC-funded project in demonstrate standards Sri Lanka where an R & for quality assurance, D and Training Center in improved the efficiency

a rural area is set–up to New Technologies for of machineries used, Manufacturing demonstrate improved develop skills of New Technologies for Floor Carpet Manufacturing work conditions and operators and prove that best practices in coir productivity and processing. profitability can be achieved.