Our Process
From Husk to Harvest – A Fully Controlled Production Journey
At Vergrow, every step in our production is carefully monitored to ensure that our coco peat substrates meet international standards of quality, cleanliness, and crop performance. By managing the entire process in-house – from raw husk collection to final shipment, we ensure traceability, consistency, and sustainability at scale.
Here’s a look at how we transform coconut husks into high-performance growing mediums:
1. Ripe Husk Selection
We start with the careful selection of mature, high-fiber coconut husks sourced directly from trusted farms in Pollachi and surrounding regions. Quality begins at the origin and we make no compromises.
2. Husk Crushing
The selected husks are mechanically crushed to separate coir fibers from the pith. This initiates the substrate formation process while preserving structure and consistency.
3. Ageing Process
The crushed material is left to age in open curing yards. This natural fermentation process helps to reduce salt content and stabilize the material for further processing.
4. Washing
Depending on customer requirements, the coir pith is thoroughly washed with fresh water to reduce EC (Electrical Conductivity) levels. We offer washed, semi-washed, and buffered options to suit different crop needs
5. Drying
The washed coir is moved to our 100,000 sq. ft. covered drying yard, allowing controlled drying regardless of the weather. This ensures consistent moisture levels and prevents microbial growth.
6. Screening
Once dried, the material is screened to remove dust and separate particle sizes. This is critical to ensure optimal aeration, moisture retention, and structure in the final product.
7. Mixing Process
In this step, coir pith, coir chips, fibers, or additives are mixed in custom ratios. Our mixing lines allow us to create crop-specific substrate blends tailored for different climates, irrigation systems, and root requirements.
8. Pressing
The blended substrate is compressed into desired formats — including 5kg blocks, 650g bricks, grow bags, open-top bags, and slabs — using semi-automated machinery that preserves quality and uniformity.
9. Packing and Palletizing
Finished products are packed using moisture-resistant packaging and stacked on pallets. Each package is labeled and coded for traceability, quality assurance, and client reference.
10. Logistics
We manage outbound shipments through a hybrid model, working with trusted freight partners and offering client-specific logistics solutions. Our proximity to Tuticorin Port ensures timely delivery across the Middle East, Europe, the UK, Asia, and the America.
