What is made in Alappuzha
Alappuzha is still called Alleppey in trade and in the DGFT list. The GI application for Alleppey Coir dates the start of the coir products industry here to 1859, beginning with coir door mats and later adding mattings and other products. The GI is registered in class 27, which covers floor coverings. The table shows the main coir product types and what we check on each.
| Product | Typical construction | Key inspection points |
|---|---|---|
| Woven coir mats | Coir yarn woven on handlooms or power looms, often dyed in patterns | Size and squareness, weight, edge binding, colour against sample, shedding |
| Tufted coir mats | Coir tufted into a PVC base, plain or printed | Tuft density and pull-out, PVC bond, print rub and spelling, odour |
| Mattings and rugs | Coir woven in rolls or cut and bound to size, sometimes with latex backing | Roll length and width, weave pattern, binding, backing, moisture |
| Coir pith | Aged, washed or buffered pith pressed into blocks or grow bags | Block weight, expansion, foreign matter, pallets, lab samples |
2026 fibre prices. Kerala Kaumudi reported on 1 July 2026, from Alappuzha, that coir fibre bought from Tamil Nadu had risen from about ₹40–42 a kilo in May to ₹72–76, and that exporters had withdrawn from foreign orders of more than 1,000 tonnes in a month. When raw material costs jump, mats can get lighter or thinner. Confirm your supplier's capacity and price, and ask for weight checks against the specification.
What we check for Alappuzha coir products
| If you buy | Main checks | Checklist |
|---|---|---|
| Doormats, woven or tufted | Tuft density and pull-out, shedding against a reference mat, PVC or rubber bond, thickness and weight, print, flatness, moisture | Doormat inspection |
| Coir pith, blocks and grow bags | Count, block weight and size, expansion, foreign matter, grow-bag film, sealed samples for EC, pH and seeds | Coir pith inspection |
| Mattings and larger rugs | Roll or rug size, weave, binding, colour, backing, moisture and mould | Rug and carpet inspection |
The jute and coir inspection page explains why moisture is always the first check. Two rules come up on most coir mat orders. In the EU, a soft PVC backing is plasticised material, so phthalates are limited under REACH; in California, they fall under Proposition 65. In the US, mats within the small rug sizes are covered by the 16 CFR 1631 flammability rule. All of these are lab results. We pull and seal backing and mat samples at the inspection and send them through lab testing coordination.
Common defects in coir mats and mattings
| Defect | Typical cause | Class |
|---|---|---|
| Mould on mats, mattings or packing | Fibre packed damp or stored wet | Critical |
| Coir tufts pulling out or lifting from the PVC | Low tuft density, poor bond at curing | Major |
| Mat lighter or thinner than specified | Less fibre per mat to save cost | Major |
| Misspelt or wrong printed text | Old screen or artwork used | Major |
| Size out of tolerance or not square | Loom tension, uneven trimming | Major or minor, by amount |
| Colour differs from the approved sample | Different dye batch for the yarn | Major or minor, by severity |
| Curled corners, uneven tuft trim, loose binding threads | Storage, finishing | Minor |
Coir sheds by nature. Agree an acceptable level on a reference mat before production, so the inspector judges shedding against something you approved.
Timing and logistics
- Monsoon: Kerala's south-west monsoon, from about June to September, is the high-risk period for damp coir. We take moisture readings on mats and inside bales, and look at storage on the day.
- Port: Alappuzha is south of Kochi, where DP World runs the container terminal. If goods are stuffed at the factory, container loading supervision checks the count, bale and carton condition and a dry container; ask the factory about a container liner and desiccant.
- Several units: weaving, tufting, printing and packing can be done in different units. A during-production inspection catches size, weight and print problems before the whole order is made.
- Combining visits: a coir factory in Alappuzha and a loading or second factory around Kochi can often be planned on one trip.
How to book an inspection in Alappuzha
Send the product, the factory's address and the ready date through the booking form for Alappuzha. Include mat size, weight and pile thickness tolerances, print artwork, the reference mat for shedding, and any phthalate or flammability reports you hold.
The inspection is US$249 per man-day. Alappuzha is in Band C, so travel is charged at actual cost and quoted before you book; see pricing. Within 24 hours we confirm the inspector, notice and price. The report arrives within 24 hours of the inspection, with a verdict of Cleared to load, Hold or Not cleared.
Sources
- GI Registry, application 54: Alleppey Coir (Coir Board; certificate 34, 16 May 2007)
- Alleppey Coir: GI application statement of case (oriGIn database)
- DGFT, Appendix 1B: List of Towns of Export Excellence (Alleppey: Coir Products)
- Kerala Kaumudi: coir export crisis, rising costs and government dues (1 Jul 2026)
- eCFR, 16 CFR 1631: surface flammability of small carpets and rugs
Are you a quality inspector in Alappuzha?
We work with vetted freelance inspectors near the factories we check. You take assignments in your own area, inspect to our checklist, and Clear To Load pays you, never the factory. Apply to inspect with us.