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How Quality PVC Coir Logo Door Mats Are Made

29th March 2020
How Quality PVC Coir Logo Door Mats Are Made

If you’re a business owner, you may have experienced buying doormats for your entrances that fray, fade, and fall apart after just a few months of use. And, after constantly replacing them, you see their lack of durability and quality soon becoming apparent as you struggle to find entrance doormats that can withstand the daily wear and tear of high-level foot traffic. In this article, we'll take you through the process of making quality PVC coir logo door mats. You'll learn about the materials used, the manufacturing process, and some benefits these mats can provide. 

How quality PVC coir logo door mats are made

If your only experience with PVC coir matting is walking over it as you enter a building, you’re not alone. But manufacturers must follow several steps to create a high-quality PVC coir logo doormat that looks great and lasts for a long time. So if you've ever wondered how this type of quality PVC coir matting is made, here's a brief overview of the process:

Harvesting and husking

Coir is a tough, natural fibre and a renewable resource that comes from the outer husk of coconuts. The coconuts are harvested by hand from trees reaching a height of up to 80ft, with each tree producing up to 100 coconuts a year. Once the harvest is collected, the coconuts are de-husked by hand or with the help of machines that speed up the process to take the outer layer off.

Retting and beating

After the husk has been removed, it’s soaked in freshwater or saltwater for up to 10 months, depending on the type of husk, encouraging the natural growth of microbes. This process, known as retting, allows the microbes to eat the softer parts of the coconut fruit, leaving the raw coir. The remaining part contains the fibres that go into coir matting. But it also has coconut dust or coir pith unsuitable for use and is discarded or added to fertiliser.

The extracted coir then goes through a beating process with machine beater arms inside steel drums that loosen and de-fibre the pulp. The loosened fibres then go through a slow-rotating drum to separate the fibres by their length. Only medium and longer-length fibres go into the coir mat-making process, while shorter lengths unsuitable for coir matting become padding material. The harvested coir is then cleaned and sundried to remove debris or residual moisture. 

Spinning and bundling

All the suitable cleaned and dried coir fibres are then gathered and spun into a type of yarn. This process can be done by hand but is more often completed using specialist spinning machines. The yarn is then wound into bundles and shipped to manufacturers ready to be assembled into various shapes and sizes. 

Adding PVC backing

Adding a robust PVC backing is one of the most important parts of the process. Once cut to the required length of 17mm for Disability Discrimination Act (DDA) compliance, the fibres are laid upright into a strong liquid PVC material. After this dries, the final PVC-backed coir mat can be produced.

Adding your logo

Whatever the shape and colour of your logo, it can be faithfully reproduced into coir matting for the ultimate in branded goods. Coloured coir fibres come in a range of 11 pre-dyed colours that can be used to recreate your logo and brand colours as closely as possible – and last the life of your mat. These elements are then cut to shape and hand-inlaid into the corresponding holes in your mat.

Pressing and trimming

When the cut and inlay process is complete and your logo appears as it should, the mat is firmly pressed to ensure the PVC backing and the coloured coir fibres are secure. When completely bonded, any excess coir material is trimmed, creating a clean finished edge and surface to the mat ready for use.

The entire process of creating any PVC coir matting makes for a durable, functional, and long-lasting mat that can withstand the wear and tear of daily use – and looks professional and eye-catching.

The benefits of PVC coir logo door mats

Slick, tiled floors are an exceptionally good-looking finish for showrooms and shops, as well as hotel, office, and other commercial entranceways. But in wet weather, moisture and shoe debris can make tiled floors a major slip hazard. 

When fitted into dedicated mat wells in these areas, PVC coir logo doormats provide a hardwearing, effective way to remove this moisture and debris for a clean, dry, and safe floor surface. But their benefits don't stop there – what else are PVC coir logo doormats good for?

Company branding

Brand visibility is essential, and incorporating your logo into your entrance matting is a bold, visible, and perfect way to reinforce your brand with impact. With a highly professional and business-like finish, your customers will be welcomed, knowing they're in the right place.

Versatile sizing

PVC coir logo doormats can be customised to a shape and size that matches the available space with no compromise to your requirements. Together with the choice of colours available, you have a completely versatile product that can be up to 5m x 2m in size to fit almost any entranceway.

Universal accessibility

All PVC coir logo doormats from Mats Direct are 17mm thick, providing universal access for all, including wheelchairs, and complying with BS8300 DDA regulations. The mats fit inside specialist mat wells for an even surface and are never loose-laid, which could pose a slip or trip hazard. 

Quality PVC coir logo doormats from MatsDirect UK

There are plenty of good reasons to invest in PVC coir logo doormats for your business, and this article will give you an understanding of how the process used to create them makes them such a popular, hardwearing, and versatile product.

To bring all these benefits into your business, MatsDirect UK offers you a range of PVC-backed coir matting that includes your logo and branding to give you safe and effective entrance matting. Contact us today by sending us a message, calling the team on 0161 797 6785, or emailing us at, and we’ll create a bespoke product for your premises.



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