Containers filled with spools of coir yarn arrive at our manufacturing facility in South Carolina from the Malabar Coast of India.
A creel with more than 300 spools feeds the yarn into a vinyl back tufting machine.
The yarn is chopped and tufted into a liquid PVC backing.
The material is heated to solidify the backing and then cooled on a long bed.
Giant stamping machines cut out the doormats in an assortment of sizes.
Designs are electrostatically flocked onto the mats on rotating carousels.
The mats go through an oven on carts to ensure the design adheres permanently to the mat.
The doormats are placed on a shaker to remove excess fiber before being tagged and packed.
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