So my host father in Alleppey told us that he was into “exports.” We assumed something super sexy because he was a pretty suave gentleman. Kind of like a James Bond villain, but nice. He just had a very crisp English accent and was always impeccably dressed. Plus he can’t be Bond because Daniel Craig is Bond. Duh. Anyway, he offered to take us nosy Americans to his factory. His coir factory. Do you know what coir is? It’s coconut husks. Do you know what coconut husks make?
Doormats! The man is a doormat millionaire. Crazy right?? And I would have NEVER guessed that those kinds of mats were made from coconut husks. My mind was blown. I also learned that it takes 25 husks to make one mat. We toured the factory and learned all of the facets of the mat business. Seriously wild stuff.
The mats are dried in the sun after they are made.
The edges aren’t clean, so this guy feeds them through a machine to make them perfectly straight.
They have graphic designers who create all of the patterns and colors for the mats.
This guy creates the metal stencils by hand. He creates one stencil per color used on the mat. The stencil set he was working on required 8 separate ones for all of the colors. Pretty sure he hates whoever decided that a peacock mat was a brilliant idea.
This gentleman manually cuts out pieces for mats that don’t require the entire square. Almost everything is done by hand which explains why those things are so expensive. I shall never gripe again.
These guys paint on the colors and designs using the stencils.
Meow meow. I know some of y’all are just dying for that mat right now. DYING. Go play with your cats and relax. The ladies below attach the rubber to the mats and apply the finish.
His products are sold all over the U.S. and in my favorite store:
It was super exciting to visit there, I have learned so much. After the mat fest, we headed to home to clean up for a Rotary meeting at my host’s house. Rich people sure know how to throw a nice party.
Best meeting yet. Probably because they had mojitos. And freshly baked rolls.
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I feel like i just watched the show how it’s made. Did you get the kitty mat? I feel like that’d be an awesome addition to the Kitty cave.
I do have the kitty mat. How unsurprised are you?
I’m not shocked at all…at all.
I can’t believe how much work goes into those mats!
I never thought that someone could get super rich off of doormats. That is all kinds of awesome. I want my own innocent household product empire.
Are you wearing David Spade’s jacket in that one pic? Sorry, I know you’re no one’s doormat…
HA!
I think I’ve had too much rice. Clearly a fat guy in little coat is happening here.
Amazing ergonimically incorrect work for those two men on the floor. Wow, how do they do that all day. I complain if the centre of my padded mouse-pad starts to get a little deflated.
I was literally thinking something very similar. If my monitor is a half inch too low, it’s like the world has ended.
Huh. I love geeky dumb stuff like mat situation. It never occurred to me to wonder how doormats were made, I always get pissed that they cost so much, and I have to replace them so often.
Never complaining again.
I’m fascinated!!! Now I think those mats are worth every penny!
LOVE the doormats….LOVE them. AND the fact that they are available at my favorite store is a bonus. Shopportunity is knocking.
you are so lame for saying shopportunity
You KNOW you are lovin it on the inside. Don’t be ashamed. :-)
You’re lame for thinking it’s lame.
:)
Okay but where are the puppy mats? Will have to go look this weekend because we seriously need a new one.
Bardot likes kitty mats so she can haughtily walk all over them.
Makes sense…especially for Bardot. She is so NOT a fan of the neighbor’s cat! Grumpy just grufs at him…Bardot and Hedi make sure to guard the yard from cats!
What is the name of the mat company as I would be interested in contacting them. Great information and pictures
Btw…emailed you some Aggie poses as suggested on earlier posts…enjoy! Mwahhhhhh
I wanna see those!