PVC / Vinyl Coir Mats

Coir yarn, produced as a machinewoven string from coir fibre, is tufted into a heated vinyl sheet on a conveyordriven tufting line. The PVC layer is brought to approximately 150 °C, allowing the molten vinyl to encapsulate and lock the cut coir tufts. As the yarn passes through the cutting and tufting heads, it is mechanically chopped into uniform pile segments and embedded into the moving vinyl substrate.

This process delivers superior pile consistency, structural rigidity, and longterm durability compared to traditional loomwoven mats. Vinyl backing thickness typically ranges from 3 mm to 5 mm, depending on grade and application. The finished product is manufactured in continuous rolls and later converted into customsized mats. The smooth vinyl base enables highquality surface printing, making the mats suitable for decorative and branded designs.

Tufting ensures uniform pile density, enhanced appearance retention, and excellent performance under repeated foot traffic.