Complete Technology Book of COIR PRODUCTS AND JUTE GEO-TEXTILES WITH COIR PITH, COIR CORRUGATED ROOFING SHEET, COIR MATTRESSES, RUBBERISED COIR, COIR GEOTEXTILES,COIR FIBRES, COIR FIBRE BOARDS AND ALLIED PRODUCTS MANUFACTURING

The book covers: Composition of Coir Pith, Coir Corrugated Roofing Sheet manufacturing Unit, Coir fibre reinforced green polymeric composites for injection Moulding Products, Using Coir Pith for Absorption and Recovery of Oil, Benefits of Pyrolysis Oil production from coir pith, Self Curing Concrete Using Coir Pith as Fine Aggregate, Coir Mattresses, Rubberised Coir Classification, Rubberised coir fibre liners for manufacture of coir garden articles, Coir Fibers as Pulp and Paper, Coir Mulch Needle Punched Non-Woven Fabric for Agro-Application, Use Of Coir Geotextiles In Unpaved Roads, Coir Geotextile - A Sustainable Reinforcing Material For Pavement Construction, Coir Fibre and its Application as Erosion Control Mats, Effectiveness of coir geotextiles in soil moisture conservation, Medium Density Coir Fiber Boards, Composite Applications using Coir Fibres, Jute Geo-textiles, Manufacturing process of Jute Geotextiles (JGT), The Full Scale Experimental Wall, Asphalt-Geotextile barriers for waste containment, Oil Retaining and Treating Geotextile for Pavement Applications, Application of Geotextiles in Pavement Drainage Systems, Equipments available in india for testing jute Geotextiles, Plant Economics of Gunny Bag Manufacturing Plant, Plant Economics Of Jute Garments, Plant Economics Of Jute Yarn, Jute Sutli & Hessian Cloth Weaving Integrated Unit,

CONTENTS

1. Composition of Coir Pith 

Structure of coir pith 

Properties of Coir Pith 

Export Potential of Coir Pith 

Environmental Impact due to Coir Pith Hillocks 

Agri / Horti Uses 

Growing Media 

As Amendment 

Coir Pith Blocks and Discs 

As a substitute to Peat Moss 

As an Organic Fertilizer 

Biological Treatments for Enhancing

Coir Pith (Conventional process) 

Method of composting 

Modification of existing composting process 

Provision of perforated PVC pipes 

Properties of C-POM 

Significance of Organic Manure 

Requirement of Coir Pith Organic Manure (C-POM) 

Composting of Coir Pith

Substituting Urea with Natural Supplements 

Azolla -Soya hulls combination 

Azolla pinnata 

Soya hulls 

Azolla -Fish waste combination (2:1) 

Cyano bacteria 

As a Base for Home / Vertical / Roof Garden 

Laying Methodology for Roof Lawns 

Potting Media 

As Soil Substitute 

Coir baskets 

Industrial Applications 

For Active Carbon for SiC (Silicon Carbide) 

Carbonization Process 

As a Source of Power Alcohol 

Production of Cellulase 

Extraction of Sodium Lignosulphonate 

Extraction of Sodium Lignosulphonate 

Uses of Sodium Lignosulphonate 

Nanocellulose from Coir Pith 

Production of Bio ethanol 

Conversion of coir pith to nanocellulose 

Production of Bio Oil 

Preparation of Particle Board 

As an Insulator 

Production of Vanillin 

Production Activated Carbon 

Steam Activation 

Chemical Activation

Coir Pith Polyester Composites 

Coir reinforcement 

Mould releasing agent. 

Moulds 

Method 

Binder less Coir Wood 

Drying of the materials 

Sieving 

Hot pressing 

Effect of Moisture 

Effect of Temperature 

Effect of pressure and cooling under pressure 

Machining 

As a Carrier Material 

Extraction of natural dyes out of coir pith 

Expansion Joint Filler 

Value addition of Tender Coconut Husks 

Production of Pulp and Paper 

Important features of the paper making

machine for coir 

2. Coir Corrugated Roofing Sheet manufacturing unit 

Introduction 

Materials and Methods for the Manufacture of

Coir Corrugated Sheets 

Coconut coir non-woven felt 

Woven bamboo mat 

Resin 

Raw materials for resin manufacture 

Test Methods To Assess The Quality of Cardanol 

Resin kettle or Batch resin reactor 

Consolidation of non-woven coir felt 

Machinery/ equipment:

Salient feature in manufacture of coir felt corrugated

sheet 

Moisture content of coir felt and mats: 

PCF Resin Adhesive Formulation [for bonding] 

Requirement of PCF resin 

Glue Application on the Coir Felt and Bamboo Mat 

Stabilization and Drying of Resin Coated Mats 

Assembly of Coir Felts/Mats 

Hot pressing 77

DIMENSIONING AND FINISHING 

Machinery and Equipment 

3. Coir fibre reinforced green polymeric composites

for injection Moulding Products 

Introduction & Scope 

Literature Survey 

Coir Fibre 

Advantages of coir Fiber 

Coir Fibre Modification 

Alkali Treatment 

Silane Treatment 

Acetylation 

Benzoylation 

Composites 

Biocomposites 

Coir Fibre based biocomposites 

Poly propylene 

MAPP used as compactabilizer 

Materials 

Method 

Modification of coir fibre 

Preparation of PP-Coir Composite 

Testing & Characterization 

Density 

Water Absorption 

Heat deflection temperature (HDT) 

Hardness 

Tensile Testing 

Flexural Properties 

Impact Test 

4. Using Coir Pith for Absorption and Recovery of Oil 

Introduction 101

Manufacturing Process 

Methodology 

Performance result of the screw press 

5. Benefits of Pyrolysis Oil production from

coir pith 

Coir pith : A potential industrial residue for high

value addition 

Effective & enhanced oil absorption in Coir Pith: 

6. Self Curing Concrete Using Coir Pith as

Fine Aggregate 

Introduction 

Need for self-curing 

Purpose of internal curing 

Effects of improper curing 

Advantages of internal curing 

Constiuent Materials

Physio-chemical properties of Coir pith 

Chemical Composition of coir pith 113

Properties of cement, Fine Aggregate and

Coarse Aggregate 

Mix Proportion 

Experimental Investigation 

Preparation of Coir pith 

Batching of Materials 

Mixing of materials 

Casting 

Internal Curing 

Period of curing for conventional cubes 

Result And Discussion 

Weight density test

Compressive strength test (IS 516 1959) 

Flexural strength test (IS 516 1959) 

Impact Test (IS 516 1959) 

Cost Analysis 

Conclusion 

7. COIR MATTRESSES 

Introduction 

Product & Its Application 

Desired Qualifications For Promoter: 

Market Potential And Marketing Issues, If Any 

Raw Material Requirements 

Rubberized coir formulation process of manufacture 

List Of Machinery

 Coir Sheet Machine (Sheeting Line) 

Coir Rope Untwisting Machine 

Hydraulic Press

Band Saw Cutting Machines 

Ball Mill 

Vulcanizing Chamber 

Tank 

8. Rubberised coir Classification 

Rubberised Coir Industry 

Natural Rubber Latex – Its Source,

Composition and Properties 

Composition ot'NR latex 

Main function of (he latex 

Raw Materials for rubberized coir mattress 

Natural Rubber Latex Concentrates 

Centrifuged Latex 

Evaporated Latex 

Creamed Latex 

Preservatives 

Curled Coir Rope 

Manufacturing Process of Rubberised Coir 

Choice of fibre for Rubberised coir

mattresses/cushions 

Curling 

Pre arrangement of fibres 

Spraying 

Drying 

Quality of rubberised coir mattress 

Characteristics of Rubberised Coir cushion 

Applications of Rubberised 

Quality parameters for Rubberised Coir Mattress 

Latex foam backed coir matting 

Spreading Process 

Advantages 

9. Rubberised coir fibre liners lor manufacture of

coir garden articles 

Advantages of pots manufactured from rubberised

coir fibre liners 

Coco Pols 

Coco poles or Plant climbers 

Coir Fiber Liners 

Coir Fiber Disks 

Hemi spheres from Coir fibre Mners 

Decorative articles from coir 

Rubber backed coir mats/ Matting Tiles 

Advantages of Rubber Backed Coir Mats/ Matting

Tiles 

Fire retardant finishes to Rubberised Coir 

10 Coir Fibers as Pulp and Paper 

Introduction 

Materials and methods 3

Material 

Morphology 

Chemical pulping 

Preparation of laboratory paper making

and characterization 

Statistical analysis 

Results and discussion 

Morphological characteristics 

11. Coir Mulch Needle Punched Non-Woven

Fabric for Agro-Application 

Introduction 

Methodology 9

Materials and Methods 

Selection of Raw Material 

Fabric Formation 

Non-Woven 

Needle Punching Technique 

Machine Detail 

Specification 

Fabrication 

Finishing's 

Treatment of Natural Glue with Coir Mulch Sample 

Ingredients 

Process 

Analysis 

Environmental Conditions 

Measurements 

Plant growth parameters 

Testing's

Result and Discussion 

Visual Analysis 

Comparative Study of Soil Temperature and

Weed Control Measures 

Competition of Synthetic Mulch with Coir

Mulch in the Growth of Fenugreek Plants for

Water Conservation 156

Comparative Growth Rate of Fenugreek Plant 

A field survey on awareness, utility and

usage of mulching 

Air and water permissibility of coir mulch 

Level of satisfaction on coir mulch 

12. Use Of Coir Geotextiles In Unpaved Roads 

Introduction 

Subgrade Separation And Stabilization 

Typical Solutions 

Geotextile Solution 

Geotextile Benefits

Bask Reinforcement

Typical Solutions 

Geotextile Solution 

Drainagl / Filtration 

Coir As A Suitable: Geotextile Material For Roads 

As Reinforcement 

As separator 

As filler/drainage layer 

Strength of suhgrade 

Field Installation of Geotextile 

13. Coir Geotextile - A Sustainable Reinforcing

Material For Pavement Construction 

Introduction 

Coir Geotextiles For Strengthening Soft Soil

Subgrade 

Present Status 

Geotext1le In Unpaved Roads 

Separation 

Lateral Restraint 

Tensioned Membrane Effect

Application of Geotextile Separation 

Filtration 

Reinforcement 

Scaling Function 

Laying of Coir Geotextiles 

14. Coir Fibre and its Application as Erosion Control

Mats 

Introduction 

Mechanism of erosion control 

Characteristics And Standard Specification

of Coir Based Erosion Control Mats 

Characteristics of coir fibre 

Chemical campoaitian of coir and other natural

fibres 

Specifications 

15. Effectiveness of coir geotextiles in soil

moisture conservation 

Introduction 

Materials and Methods 

Results and Discussions 

Crop: Bhindi 

Effect of mulch on growth parameters 

Effect of mulch on height of plants 

Effect of mulch on Number of leaves 

Effect of mulch on lateral spread of the plant 

Effect of mulching on yield parameters 

Effect of mulch on weed intensity 

Effect of mulch on yield parameters 

Length of fruits as influenced by mulch (cm) 

Effect of mulch on weed intensity 

Effect of mulch on soil temperature 

Effect of mulch on soil moisture 

16. Medium Density Coir Fiber Boards 

Introduction 

Materials And Methods 

Preparation of Medium-Density Coir Boards 

Chemical Treatment 

LOI Test 

Determination of Fire Resistance 1

Results and Discussion 

17. Composite Applications using Coir Fibres 

Introduction 

Study on products and materials 

Investigation of current status of coir

composite research 

Fibre cleaning procedures 

Fibre chemical treatments 

Chemical modification 

Graft polymerisation with MMA: 

Acetylation 

Other findings in literature 

Acrylic resins as binder: 

Natural fibre composite based on processing

technology 

Natural fibre composite in application:

Conclusions of literature research

Investigation of material and technological

properties of coir for composite manufacturing 

Research on micro-scale has been carried out at 

Appropriate combinations of products

and technologies 

Identifying potential marketability of coir

composite products 

Raw materials 

Coir Fibre 

Polymer 

Technology and products 

Market for coir based composites 

Technology development 

Raw materials 

Manufacturing of composite specimen 

Vacuum Injection Technology 

Latex and Monomer Impregnation 

Prepregging with MMA monomer 

LFT processing 

Materials used

Procedure of the trials 

Effect of treatments on the properties of

composite specimen 

Prototyping 

Vacuum Injection 

Compression Forming with thermoplastic prepregs 

LFT 18. Jute Geo-textiles 

18. Jute Geo-textiles

Composition and Characteristics of Jute Fibre 

Tenacity 

Elongation 

Flexural Rigidity and Torsional Rigidity 

Hygroscopicity 

Thermal behaviour 

Structure of Jute 

Properties of Jute Fabric

19. Manufacturing process of Jute Geotextiles (JGT) 

Separation 

Filtration 

Drainage 

Initial Reinforcement 

Control of Surface Soil detachment 

Bio-technical Support 

Transportation, Storage & Handling of JGT

Storage 

Site unloading 

Site Handling 

Installation 

Properties of JGT and Important Test Methods 

Physical Properties 

Physical Properties 

Mass per unit area 

Thickness 

Porometry (AOS 

By Microscope 

By Reverse Dry Sieving Technique 

By Wet Sieving 

Drapability 

Mechanical Properties 

Tensile Strength 

Puncture Strength 

Burst Strength 

Tear Strength 

Frictional Resistance 

Hydraulic Properties 

Soil Permeability (ks) 

Permittivity of JGT 

Transmissivity 

Determination of clogging potential of JGT 

Durability of JGT 

Bitumen as water-repellent 

Utilization of Palm-mat Geotextiles to

Conserve Agricultural Soils 

Objectives 

Analyses of Selected Mat Properties 

Computation of Effectiveness of Geotextile-covered

Plots 

Statistical Analysis 

Results 

Selected Physical Properties of the Mats 

Splash Erosion 

Runoff Volume 

Sediment Yield 

Geotextile Reinforced Walls 

20. The Full Scale Experimental Wall 

21. Asphalt-Geotextile barriers for waste

containment 

Hydraulic conductivity of FAA-GT 

Vapor transmission rates for FAA-GT 

22. Oil Retaining and Treating Geotextile for

Pavement Applications 

Development of the Geotextile 

Initial Biofilm Experiments

Hydrocarbon Retention Experiments 

Retention Experiment 1 

Retention Experiment 2 

pavement sections 

23. Application of Geotextiles in Pavement

Drainage Systems 

Physical properties 

Mechanical properties 

Hydraulic properties 

Endurance properti

Types of Geotextiles 

Woven fabrics 

Non-woven 

Knitted fabrics 

Function of Geotextile in Drainage 

Advantages of using Geo-textile in Drainage 

Conclusion 

JGT Manufacturing Process Photographs 

24. Equipmnets available in india for testing jute

Geotextiles 

25. Plant Economics of Gunny Bag Manufacturing

Plant 

Plant & Machinery 

Fixed Capital 

Raw Materials 

Total Working Capital/Month 

Total Capital Investment 

Turn Over/Annum 

26. Plant Economics Of Jute Garments 

Plant & Machinery 

Fixed Capital 

Raw Materials 

Total Working Capital/Month 

Turn Over/Annum 

27. Plant Economics Of Jute Yarn, Jute Sutli & Hessian

Cloth Weaving Integrated Unit 

Plant & Machinery For Jute Yarn: 

For jute sutli 

For Hessian Cloth 

Fixed Capital 

Raw Materials For Jute Yarn 

For Jute Sutli 

For Hessian Cloth 

Total Working Capital/Month 

Turn Over/Annum 

LIST OF TABLES

Table 2.1: Coir corrugated sheet - 3 ply 

Table 2.2: Coir felt corrugated sheet - 5 ply 

Table 2.3: Other Test performed on coir felt corrugated sheets 

Table 3.1: Chemical Composition of coir fibre

Table 3.2: Physical Properties of Coir Fiber

Table 3.3 Formulations for compounding 

Table 4.1. Results of proximate analysis 

Table 6.1: Chemical composition of coir pith 

Table 6.2 Properties of cement, Fine Aggregate and Coarse Aggregate 

Table 10.1. Soda-AQ pulping condition for coir fibers. 

Table 10.2. Full factorial DOE coir pulping settings.

Table 10.3. Fiber characteristics of coir fiber.

Table.11.1: Comparative study of mulch sheets

towards moisture retain and weed control 

Table 14.1: Chemical composition of coir fibre 

Table 14.2: Properties of various fibres 

Table 14.4; Typical specifications of Natural Geotextile

(MARV*) using Coir (MoRTH 700) 

Table 15.1 Height of plants Vs different treatments for Bhindi crop 

Table 15.2 Number of leaves Vs different treatments for Bhindi crop 1 (xxiv)

Table 15.3 Lateral spread Vs different treatments for Bhindi crop 

Table 15.4 Effect of mulching in different treatments for Bhindi crop 

Table 15.5 Weed Intensity Vs different treatments for Bhindi crop 

Table 15.6 Variation in fruit parameters with different treatments for Pineapple crop 193

Table. 15.7 Weed Intensity Vs different treatments for pineapple crop 

Table. 15.8 Soil temperature Vs different treatments 

Table 15.9 Soil temperature Vs different treatments 

Table 16.1. Consolidated results of flammability,

flame penetration, and rate of burning tests. 

Table 18.1: Composition of Jute Fibre. 

Table 18.2: Comparative physical properties of Jute

and Other Fibres. 235

Table 18.3: Properties of some typical Jute Geotextiles 

Table 18.4: Open mesh woven jute geotextiles

(IS Specifications) 238

Table 18.5: Woven Jute Geotextiles 

Table 18.6: Nonwoven Jute Geotextiles

(Indicative Specifications) 

Table 18.7: Properties of Pre-Fabricated Jute Drain

with Coir Wicks 239 (xxv)

LIST OF FIGURES

Fig. 1.1 Scanning Electron Microscope of raw coir pith 

Fig. 1.2 Leachate from accumulated coir pith washing.

Fig. 1.3 Grow bags filled with coir pith for plant cultivaton 

Fig. 1.4 Utilization of coir pith as amendment in crop cultivation 

Fig. 1.5 (a) Pleurotus sajor caju - Culture on PDA 

1.5 (b) Fruiting body in natural condition 

1.5 (c) PITHPLUS 

Fig. 1.6 Schematic diagram of aerator tube assembly 

Fig. 1.7 Demonstration of PVC aerator tube assembly 

Fig. 1.8 Pilot demonstration on coir pith hillock

composting (250 tons) 

Fig. 1.9 SEM view of C-POM 

Dosage (per annum) for application of

C-POM on different crops 

Fig. 1.10 Structural concepts of vertical garden 

Fig. 1.11 Demonstration of Vertical Garden 

Fig. 1.12 Bridge in France with Vertical Garden 

Fig. 1.13 Roof gadening 

Fig. 1.14 SEM view of C-POM 

Fig. 1.15 Conversion of coir pith to nanocellulose 

Fig. 1.16 Coir Polyester Moulded Products 

Fig. 2.1: Coir Corrugated Sheets - Process Flow Chart 

Figure. 3.1 Coir Fibre 

Figure. 3.2 Extraction of Coir Fibre 

Figure 3.3 Commercial applications of coir fiber 87

Figure 3.4 Influence of alkali treatment on cellulose

structure 89

Figure 3.5 Polypropylene 93

Figure 3.6 Reaction mechanism of Cellulose with MAPP 

Figure 3.7 Specimen of testing Sample 

Fig 4.1. Block diagram showing the process and

components 

Fig. 4.2. Hydraulic press used during experiment 

Fig. 4.3 Oil recovery from the coir pith 

Fig. 4.4. Drawing of the screw press 5

Fig. 4.5 (a). View of the screw press 

Fig. 4.5 (b). View of the screw press 

Fig. 4.6. Oil extracted from the coir pith using

the screw press 

Fig. 4.7. Oil absorbed in to coir pith 

Fig. 4.8. Coir pith to oil absorption 107

Fig. 5.1 A view of the Pyrolysis oil produced from Saw

dust using a proto type reactor 109

Fig. 5.2: View of a pyrolyser rector (proto type) used

for conversion of biomass in to liquid fuel 

Fig. 5.3 The process of oil recovery using coir pith 

Fig 6.1 Preparation of coir pith 

Fig 6.2 Mixing with water 

Fig 6.3 Mixing coir pith with cement 

Fig 6.4 Removal of water by squeezing 

Fig 6.5 Mixing with concrete specimen the coir

pith concrete 

Fig 6.6 Moulding of concrete 

Fig 6.7 Moulding of concrete specimen 

Fig 6.8 Moulding of cube prism. For impact test concrete (xxvii)

Fig 6.9 Schematic diagram of Internal Curing 

Fig 6.10 Curing of concrete specimens

Fig.11.1: Natural Gum 

Fig.11.2: Dissolved Glue with Coir Sample 

Figure 11.1 Shows the solid form of neem and babul

gum and Figure 11.2 shows the glues in semisolid form. 

Fig: 11.3 Application of Coir Mulch on Soil Surface 153

Fig. 12.1 Geotextile as Separator 

Fig. 12.2 Reinforcement Action 

Fig. 12.3 Drainage Application 

Fig. 12.4 Variation of Peak Shear stress vs. Normal Stress

for red soil - Coir Geotextile Interface 

Fig 12.5. Load Settlement behaviour with Coir geotextiles

placed at z/B = 0.5 

Fig. 12.6. Effect of Type of Reinforcement on load

penetration 

Fig. 13.1 Geotextile as a separator 

Fig. 13.2 Filtration and Transmissivity Functions

Drainage (Transmissivity) 

Fig. 13.3 Scaling Functions 

Figure 14.1 (a) Protection of road embankment

Figure 14.2: (a) Mean Stress-Strain Curve for coconut fibre (b)

Stress-Strain Curves of Natural Fibres 

Figure 16.1. Arrangement for flammability test. 

Figure 16.2. Arrangement for flame penetration test. 

Figure 16.3. Arrangement for rate of burning test. 

Figure 18.1: Photographs of Jute Plant, Jute

Figure 18.2: Jute geotextiles for control of surface soil

erosion 

Figure 18.3: Jute geotextiles for filtration and drainage 

Figure 18.4: Jute geotextiles for separation and filtration 

Figure 18.5: Prefabricated jute drains for accelerated

consolidation of soft soil 234

Figure 19.1. Schematic plan of the runoff plots at Hilton 

Figure 20.1. Cross-section of experimental full size wall. 

Figure 20.2. Saturation of an experimental full

size wall. 

Figure 21.1. Examples of asphalt concrete and fluid

applied asphaltgeotextile barrier applications. 

Figure 21.2 Sampling the field FAA-GT from the test pad

Figure 21.3 Set up for vapor transmission tests. 

Figure 21.4. Solvent vapor transmission tests showing

FAA-GT and HDPE geomembranes exposed to

xylene. 

Figure 22.1 Typical Results of Distribution of 

Throughout Osmocote Plus Treated PPS 283

Figure 22.2 Re-interpretation of Bond's

Long Term Experiment 

Figure 22.3 Initial Dynamic Retention Trial 

Figure 22.4 Cross section of larger textile-only rig 

Figure 22.5 Schematic Experimental Systems

Using Heat Bonded Polyolefin Geotextile 

Figure 22.6 Experimental systems for the new

geotextile (NPMPE) and Non-Geotextile (N-G) 

Figure 23.1: Geo-textile used for drainage. 

Figure 23.2: Geo-textile layer in sub-grade. 

Figure 23.3: Use of fabrics in drainage.

COMPOSITION OF COIR PITH

Coir waste has a high lignin (30-31%) and cellulose (26.8%)

content. Its carbon nitrogen ratio is around 112:1. Lignin is a complex

amorphous polymer of phenyl propane which surrounds the

cellulose in cell walls and is relatively inert to hydrolysis. Because

of the high lignin content left to it, coir waste takes decades to

decompose.

Coir pith has a calorific value of 3975 kcal per kg close to 4200

kcal per kg of coal and hence it can be used as fuel briquette and

also in pig iron manufacture, tobacco fluecuring, gas absorbent

cotton etc.

1.1 STRUCTURE OF COIR PITH

Lignin and cellulose work together to provide a structural function

in plants