Manufacturing & Substrate Operations
Converting natural Ceylon coconut husks into high-grade, low-salinity (low-EC) growing media via integrated mechanical grinding, solar drying, and hydraulic compaction.
Integrated 4-Stage Substrate Manufacturing Workflow
Operating a continuous processing workflow distributed across dedicated functional facility zones to deliver batch-to-batch consistency.
Raw Material Sourcing & Husk Intake Yard (5.0 Acres)
Raw coconut husks are collected directly from plantation networks across Sri Lanka’s fertile coconut processing belt. Upon arrival at the 5.0-acre husk intake yard in Mudithagama, Nochchiyagama, raw husks are segmented using mechanical slicing equipment to prepare for fiber and pith extraction.
- Sourced from local Sri Lankan coconut triangle plantation networks
- Mechanical slicing cutters for uniform segmenting
- 100% natural, eco-friendly agricultural by-product upcycling
Grinding & Fiber Separation Sector (3.0 Acres)
In the 3.0-acre grinding sector, high-speed mechanical crushers separate fine coco peat particles (coir pith) from longer, tougher coconut fibers. The extracted fiber is baled for industrial applications, while the refined coco peat enters the salinity control washing line.
- High-speed mechanical crushers & sieving drums
- Separation of fine peat pith from long coconut fibers
- High-density coir fiber baling for bulk industrial export
EC Salinity Washing Beds & Solar Drying Yards (8.0 Acres)
Raw coco peat contains natural salts. Across our 8.0-acre washing and drying sector, peat is thoroughly washed in specialized filtration beds to reduce Electrical Conductivity (low-EC <0.5 mS/cm) and stabilize pH (5.5 – 6.5). Low-EC peat is then spread across open-air yards to dry using natural solar energy.
- Washed low-EC salinity control (<0.5 mS/cm)
- Optimal pH stabilization tailored for greenhouse crops (5.5 – 6.5)
- 8.0 Acres of open-air solar drying to reach <15% moisture content
Hydraulic Compaction & Container Packaging (3.0 Acres)
In the 3.0-acre compaction workshop, dried low-EC coco peat is compressed using heavy-duty hydraulic pressing machinery into 5 kg blocks (5:1 compression ratio), 650g briquettes, and grow bag slabs. Finished goods are wrapped in polythene, palletized, or loaded into jumbo bags.
- Heavy-duty hydraulic presses delivering 5:1 compaction density
- Custom OEM product formats: 5kg blocks, 650g briquettes, grow bags
- Polythene shrink wrap, stretch wrapping, and palletization
20-Acre Facility Zone Allocation
Our 20-acre Mudithagama industrial complex is organized into 5 specialized functional zones designed for efficient throughput and quality control.
Husk Intake & Segmenting Yard
Bulk raw husk unloading, quality inspection, and mechanical slicing into uniform segments.
Grinding & Separation Sector
High-speed crushing, sieving drums, and high-density industrial coir fiber baling line.
Washing & Solar Drying Beds
EC salinity control washing beds (<0.5 mS/cm) and expansive open-air natural solar drying yards.
Hydraulic Compaction Workshop
5:1 hydraulic pressing machinery, shrink wrapping, grow bag assembly, and container loading bays.
Onsite QA Testing Lab & Administration
Comprehensive laboratory testing facilities for continuous batch monitoring (EC, pH, moisture, sand content, expansion volume) and plant administration offices.
Processing Machinery & Infrastructure
Equipped with heavy-duty machinery engineered to maintain high throughput and strict quality tolerances.
Mechanical Husk Cutters
Precision rotary slicing machinery for segmenting raw husks prior to fiber extraction.
Crushers & Sieving Drums
High-velocity separation machinery filtering fine coco pith from coarse coconut fiber.
Desalination Washing Line
Continuous water circulation beds removing sodium and chloride salts to lower EC below 0.5 mS/cm.
5:1 Hydraulic Presses
Industrial hydraulic block compaction machinery compressing dried low-EC peat into 5kg export blocks.
Onsite QA Laboratory Testing Parameters
Every single production batch undergoes rigorous quality testing in our onsite laboratory before hydraulic compaction, packaging, and container dispatch to guarantee strict compliance with commercial agricultural standards.
Washed low-salinity control below <0.5 mS/cm
Controlled pH stabilization between 5.5 – 6.5
Solar dried to maintain moisture below <15%
High substrate expansion yield per block
Request Manufacturing & Bulk Supply Quotes
Contact our export operations team to discuss custom product ratios, private labeling, and containerized dispatch schedules.