INDUSTRIAL INFRASTRUCTURE & AGRO-TECH

PRECISION MANUFACTURING PROCESS

From the fresh coconut groves of Pollachi to containerized export blocks, explore our end-to-end 6-stage lifecycle engineered for consistent Electrical Conductivity, optimum water holding capacity, and zero chemical additives.

Concrete Yard Area 150,000+ Sq.Ft Clean sun-curing concrete aprons

EC Reduction Method Freshwater Wash Triple-stage low sodium leaching

Compression Hydraulic 5:1 High Ratio Heavy-duty 120-ton tonnage press

Quality Batching 100% Traceable Sampled per 20 MT batch run

HOW WE MANUFACTURE

THE 6-STAGE PRECISION PROCESS

Every container shipped undergoes a calibrated manufacturing lifecycle to ensure stable electrical conductivity, low tannin, and certified phytosanitary cleanliness. Explore each stage below:

01 · Raw Material Sourcing

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STAGE 01 OF 06 Origin Protocol

Pollachi & Anaimalai Agricultural Corridors

Selective Agro-Corridor Sourcing

Raw coconut husks are procured directly from certified farm clusters across western Tamil Nadu. Immediate processing prevents unwanted anaerobic decomposition, securing resilient cellular structure and naturally low baseline sodium content.

Raw Material 100% Mature Husks

Pith Age Aged 6–12 Months

Traceability Farm-to-Gate Batch

INSPECTION: Zero Chemical Residue NEXT: Decortication →

02 · Decortication & Sieving

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STAGE 02 OF 06 Mechanical Separation

High-Speed Rotary Screening

Decortication & Rotary Sieving

Automated decorticating machines separate coir fibre from the spongy pith matrix. Pith is passed through calibrated 6mm and 8mm rotary trommel screens to extract ultra-fine micro-dust while keeping optimal Air-Filled Porosity (AFP).

Mesh Sieve 6mm / 8mm Trommel

Air Porosity (AFP) 18% – 25%

Micro-Dust Content < 3% Controlled

SEPARATION: Continuous Screen Calibration NEXT: Freshwater Desalination →

03 · Freshwater Washing

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STAGE 03 OF 06 Biochemical Conditioning

Closed-Loop Desalination & Buffering

Freshwater Desalination & Buffering

Substrates undergo repeated freshwater immersion cycles to dissolve sodium and chloride ions. For sensitive berry and hydroponic crops, calcium nitrate buffering displaces bound potassium and sodium, stabilizing cation exchange capacity (CEC).

Target Washed EC < 0.5 mS/cm

pH Spectrum 5.8 – 6.8 Optimal

Water Standard Deep Borewell Fresh

EXTRACTION: 1:1.5 Dutch Extraction Method NEXT: Sun-Drying Aprons →

04 · Sun-Drying Aprons

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STAGE 04 OF 06 Natural Solar Curing

Weed-Free Paved Aprons

Clean Concrete Apron Sun-Drying

Washed coir is spread on 150,000+ sq.ft of elevated reinforced concrete floors. Sun-curing under Tamil Nadu's intense solar exposure naturally reduces moisture below 18% without thermal degradation while preventing soil pathogen contamination.

Target Moisture < 18% Final

Yard Surface Reinforced Concrete

UV Sterilization Natural Sunlight

MOISTURE GAUGES: Calibrated Pin Meters Checked Hourly NEXT: Hydraulic Compaction →

Hydraulic Pressing of 5kg Cocopeat Blocks

05 · Hydraulic Pressing

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STAGE 05 OF 06 High-Tonnage Compression

5:1 High Ratio Compaction

High-Tonnage Hydraulic Pressing

Automated hydraulic presses apply up to 120 tons of linear force to compress dried coir pith into compact 5kg blocks, 650g briquettes, or grow bag slabs. The 5:1 volume ratio ensures optimal freight utilization without breaking cellular walls.

Compression Ratio 5:1 Volumetric

Re-Expansion Yield 75+ Liters / 5kg

Block Dimensions 30 x 30 x 12 cm

EDGE BEVELING: Prevents Corner Breakage in Transit NEXT: Palletization & Export QC →

ISPM-15 Palletization & Container Loading

06 · Palletization & Export QC

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STAGE 06 OF 06 Dispatch & Compliance

ISPM-15 & Phytosanitary Stamped

Palletization & Phytosanitary Stamping

Blocks are stacked onto heat-treated wooden pallets with heavy-duty edge corner guards and multi-layer stretch shrink film. Containers are stuffed with moisture-absorbing silica bags and sealed under plant quarantine inspection before dispatch.

Pallet Spec ISPM-15 Heat Treated

Container Payload 24–26 MT in 40' HC

Custom Seals Tamper-Proof RFID

CERTIFICATION: Phytosanitary & Fumigation Endorsed Book Container Batch →

STAGE 01 OF 06: SOURCING

LABORATORY QA

RIGOROUS IN-HOUSE TESTING PROTOCOLS

Our dedicated facility laboratory executes standardized batch assays before releasing blocks for container loading.

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1:1.5 Dutch Extraction EC Testing

Every production batch undergoes standardized 1:1.5 water extraction testing to verify electrical conductivity levels stay consistently below 0.5 mS/cm.

EC TOLERANCE: ± 0.05 mS/cm

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Volumetric Re-Expansion Assays

Randomly sampled 5kg blocks are hydrated in graduated verification vats to confirm expansion yield exceeds 75 liters of porous substrate per unit.

MINIMUM YIELD: 15 L / kg

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Particle Size & Sieve Analysis

Electromechanical vibratory sieve shakers verify that sub-1mm micro-particles remain under 3%, preventing compaction and root waterlogging in pots.

AIR-FILLED POROSITY: 18% – 25%