Manufacturing & Standards

Precision Manufacturing in Irugur, Coimbatore

Combining South India's rich agricultural palm belt with Coimbatore's machine-tool precision to manufacture high-durability, export-compliant tableware.

12M+ UnitsAnnual Production Capacity

140°C HeatHydraulic Precision Dies

< 8% MoistureAnti-Fungal Chamber Standard

99.9% CleanInline UV-C Germicidal Tunnel

The 8-Step Production Journey

Zero chemicals, zero deforestation, 100% natural circular lifecycle.

Step 01Continuous Sourcing

Sustainable Frond Collection

100% Fallen Agricultural Byproduct

Areca palm trees naturally shed their leaf sheaths every few weeks. Our network of partner farmers in Pollachi, Salem, and Karnataka collect these naturally fallen fronds without harming a single live tree.

Naturally detached sheaths collected directly from organic plantations

Supplements rural agricultural income for over 200+ farming families

Prevents agro-waste burning and open air emissions

✓ Zero Deforestation • Farm Income Uplift

Step 02100% Inspected

Manual Sorting & Fiber Inspection

Thickness & Purity Verification

Collected leaves are delivered to our Irugur, Coimbatore facility where our trained quality teams manually inspect and grade each frond for structural thickness (>1.5mm), natural grain texture, and the absence of biological defects.

Rigorous sorting for uniform thickness and natural color variation

Damaged or decayed fronds are diverted into agricultural composting mulch

Only top-grade, dense fiber sheaths are queued for production

✓ Strict Raw Material Rejection Protocol

Step 03Multi-Stage Rinsing

High-Pressure Fresh Water Cleansing

Chemical-Free Surface Purification

Selected sheaths are immersed in natural fresh spring water to restore fiber flexibility, then cleaned with high-pressure water jets and organic fiber brushes to thoroughly remove natural soil and farm dust without chemicals, chlorine, or bleaches.

Multi-stage pressurized washing using filtered RO-grade water

Restores natural leaf moisture for smooth, crack-free thermal molding

Closed-loop water filtration system to minimize process water waste

✓ Zero Bleaches • Zero Detergents

Step 0430-45 Seconds / Cycle

Hydraulic Thermal Compression

Precision Heated Tooling (120°C - 160°C)

Softened fronds are pressed into specialized hydraulic presses equipped with custom male/female precision dies. Operated at 120°C to 160°C under 15 to 25 tons of hydraulic pressure, the natural lignin binds the leaf into shape while instantly thermal-sterilizing the plate.

Natural lignin bonds the structure permanently without added resins or glues

High thermal exposure completely sanitizes the plate surface

Uniform wall thickness and reinforced structural rim design

✓ Custom Coimbatore Engineered Presses

Step 05Micrometer Precision

Precision Rotary Edge Finishing

Smooth, Splinter-Free Borders

Plates are conveyed to high-speed rotary trimmer stations where excess border margins are cut with micrometer precision, ensuring smooth, splinter-free, burr-free tactile edges that are comfortable for dining.

Automated rotary cutting blades ensure clean, polished perimeters

Trimmed leaf scraps are collected and repurposed into organic biomass briquettes

Zero waste generation throughout the entire finishing stage

✓ Burr-Free Edge Safety

Step 06Continuous Inline UV-C

UV-C Microbiological Sanitization

Food-Grade Cleanliness Standard

Every finished piece passes through an industrial Ultraviolet (UV-C) sterilization tunnel. This high-intensity germicidal irradiation neutralizes 99.9% of potential bacteria, mold spores, and airborne microorganisms.

Inline UV-C germicidal conveyor ensures medical-grade surface hygiene

Complies with international food contact hygiene regulations

Ensures zero bacterial residue before sealing

✓ 99.9% Microbial Neutralization

Step 07Controlled Thermal Bake

Moisture Regulation Chamber

Anti-Fungal Protection (<8% Moisture)

Products are conditioned inside our industrial dehumidification baking chambers to reduce internal moisture strictly below 8-10%. This step is critical to preventing fungal spore germination during prolonged ocean container transit.

Calibrated electronic moisture probes test batch moisture levels

Prevents mold or fungal growth across 30+ day ocean transit times

Ensures stable 24-month product shelf life in dry ambient storage

✓ Export-Grade Anti-Fungal Assurance

Step 08Export Ready

Hermetic Shrink Wrap & Export Packing

Moisture-Locked Export Master Cartons

Tableware is bundled into packs of 20, 25, or 50 pieces, inserted with food-grade silica gel desiccant sachets, and vacuum/shrink-wrapped in recyclable poly film. Bundles are then packed into heavy-duty 5-ply or 7-ply export master cartons with pallet protection.

Shrink-wrapped with moisture-absorbing food-grade desiccants

Heavy-duty 5-ply and 7-ply corrugated master cartons (burst factor > 16)

Standard Euro and ISO pallet configurations with stretch wrap and strapping

✓ Palletized & Container Optimized

Factory Location: SF No. 212/1C2, Irugur, Coimbatore

We welcome international procurement officers and wholesale distributors for on-site facility audits and sample evaluation.

Schedule Factory Inspection