Coconut craft

Retail Research on Coconut Shell Crafts
Ketaki Karkhanis | Prathima M | Harshita S K | Guide : Dr. Baral

Coconut shell Craft : 1

Table of Contents

Objective of the project Page 4 Reatil Aspects Page 60

Introduction Page 6 Retail Scenario Page 62
Origin & Distribution Page 8
Natural Habitat Page 9 New design development Page 64
Coconut Cultivation Page 10 New Designs Page 68
Coconut Craft Page 12
Bibliography Page 71
Data collection - Kerala Page 14
Craft Products Page 16
Craft Process Page 24

Data collection - Bangalore Page 42
Craft Products Page 44
Accessories Page 50
Craft Process Page 52

2 : Coconut shell Craft Coconut shell Craft : 3

Objective of The project

To create a design intervention, so that an Indian dying craft of coconut shells
could be revived and state of art could be increased.

We as design students would be transformation agents by understanding the
pulse of the trade. Intervention at the thought level ,strategic designing, market
pulse and the retail context. Looking to reach likes of home decoration , office
stationary.

Necklace made of coconut fibre Spoons made of coconut shell


Introduction

The coconut palm, Cocos nucifera, milk derived from it are commonly
the term coconut can refer to the used in cooking and frying; coconut
entire coconut palm, the seed, or the oil is also widely used in soaps and
fruit. The term is derived from 16th cosmetics. The clear liquid coconut
century Portuguese and Spanish water within is a refreshing drink and
cocos, meaning “grinning face”, from can be processed to create alcohol.
the three small holes on the coconut The husks and leaves can be used as
shell that resembles a human face. material to make a variety of products
Found across much of the tropics, for furnishing and decorating. It also
the coconut is known for its great has cultural and religious significance
versatility as seen in the many in many societies that use it.
domestic, commercial, and industrial One of the earliest mentions of the
uses of its different parts. Coconuts coconut dates back to 545A.D or
are part of the daily diet of many 1520 A.D referring to the Indian nut.
people. Its endosperm is known as the
edible “flesh” of the coconut; when
dried it is called copra. The oil and (source: www.wikipedia.com)


Origin & Distribution Natural Habitat

Origin Natural habitat
The origin of the plant is the subject The coconut palm thrives on sandy soils and is highly tolerant of salinity. It prefers
of debate. Many authorities suggest areas with abundant sunlight and regular rainfall (150 cm to 250 cm annually),
an Indo-Pacific origin either around which makes colonizing shorelines of the tropics relatively straightforward.
Melanesia and Malaysia or the Indian Coconuts also need high humidity (70–80%+) for optimum growth.
Ocean, while others see the origin in
northwestern South America. The Coconut palms require warm conditions for successful growth, and are
oldest fossils known of the modern intolerant of cold weather. The conditions required for coconut trees to grow
coconut date from the Eocene period without any care are:
from around 37 to 55 million years mean daily temperature above 12–13 °C every day of the year
ago and were found in Australia and 50 year low temperature above freezing
India. However, there are older palm mean yearly rainfall above 1000 mm (39.37”)
fossils like some of nipa fruit that have no or very little overhead canopy, since even small trees require a lot of sun
been found in the Americas.
The main limiting factor is that most locations which satisfy the first three
Source: www.gktoday.in/primary-sector-indian-economy/production-of-plantation-crops-in-india/
requirements do not satisfy the fourth, except near the coast where the sandy
Distribution soil and salt spray limit the growth of most other trees.
The coconut has spread across much
of the tropics, probably aided in many India is the third largest producers of coconut, next to Philippines and
cases by seafaring people. Coconut Indonesia
fruit in the wild is light, buoyant and
highly water resistant, and evolved
to disperse significant distances via
marine currents.


Coconut Cultivation

Traditional areas of coconut products like coconut water, copra,
cultivation in India are the states of coconut oil, coconut cake (also called
Kerala, Tamil Nadu, Karnataka, Goa, coconut meal, copra cake, or copra
Andhra Pradesh, Orissa, West Bengal, meal), coconut toddy, coconut shell-
Pondicherry, Maharashtra and the based products, coconut wood-based
islands of Lakshadweep and Andaman products, coconut leaves, and coir
and Nicobar. Four southern states pith.
put together account for almost 92% The Southern Indian state of Kerala
of the total production in the country: is named after the coconut tree.
Kerala (45.22%), Tamil Nadu (26.56%), “Kera” = Coconut tree, “Alam” = Land:
Karnataka (10.85%), and Andhra so “Land of Coconut Trees” Various
Pradesh (8.93%).[36] Other states terms like Copra, Coir are derived
like Goa, Maharashtra, Orissa, West from the native Malayalam language.
Bengal, and those in the northeast In Kerala, coconut tree is called as
like Tripura and Assam account for “Kalpa Vriksham” which essentially
the remaining 8.44%. Kerala, which means all parts of a Coconut tree is
has the largest number of coconut useful some way or other.
trees, is famous for its coconut-based


Coconut Craft

Coconut shell craft has a long history plantation and other related
and has master craftsman in the industries which provide raw material
field. It is not a traditional craft / (shell) for the crafts.
legacy, i.e. it is not passed on from a
generation to generations that have Thought lot families have been in this
a particular caste or family of the craft for long time, in recent times
society practicing the craft. It being a with mechanizations of craft and
cultivated or developed craft , person new generations inclined to current
with the skill and access to the raw professions , only a few interested
materials have taken to the craft. people are found doing this craft.
It is confined to the coastal areas Various handmade process have also
where there is abundant coconut been replaced by the machines.


Data Collection Kerala

Historically the craft has mention in We had the opportunity to visit
Malabar region where coconut shell JUPITER ENTERPRISES at cherthala.
crafts have been used to make hookas, ( cherthala is located between cochin
patronized by the kings . These were and allapuzha.)
also sent to the Arab kings . This was in a mini factory setup in the
Locally this half cut shell of the premises of his house. With around
coconut have been the waste product 2 people working . The process
of domestic use, as coconut is a major predominately was mechanized as he
part of the cooking recipes, it is almost been practicing this art /craft for last
a daily feature that this is used . 24 years.
This half shell naturally has bowl His various products included coconut
shape. Since this is a hard shell stem, shell, fibre. His house is standing
unaffected by water or heat ,this as a testimony to what is possible with
shape is conveniently used as glasses coconut wood and shells.
or to drink something. Used for paint
mixing or storage bowls in traditional
Kerala murals. Mr. Chanchu in his workshop


Craft Products

Soap Tray Ice cream cup Puttu maker


Craft Products

Various sizes of coconut shell spoons Joining details Different Table spoons and fork


Craft Products

Soup Spoons Curry serving spoon Different sizes


Craft Products

Pen Stand Key Chains


Craft Process

The process involved in sourcing the coconut shell to the finished product has
under gone drastic changes. Initially hand tools were uses to carve , cut , finish
the edges.
With advent of machines, there are lathe machines that have replaced all the
hand tools. The process is much faster.


Raw Material

Coconut is dehusked and broken to procure the flesh/kernel for various
purposes of domestic cooking, oil producing industries. As the purpose is served
the shell becomes a waste product. This waste product is the raw material for
this craft process. These shells are sourced from these industries or nearby
houses depending on requirements.

This metal device is used to unhusk the coconut


Selection of Material

The shells are hard and naturally resistant to termites and changes in
atmospheric conditions, hence it does not require any kind of treatment or
process after it is sourced. Coconut shell has a natural form of a bowl due
to its natural formation/growth. All products are developed because of this
inherent shape. A suitable shell is selected based on the products to develop.
For example, a wide coconut can be used for making soup bowls or a narrow
mouth can be used as wine glass. A skilled crafts man can see his finished
product in the raw shell that he selects. In general a shell with intent form and
thick without any cracks or breakage is considered a good shell from which a
product could be developed.

Selected coconut shell


Sanding Process

As the suitable shell is selected, next would be to clean the shell. Coconut fibers
on shell have to be removed. In a traditional way it was removed by rubbing
the shell on a stone or any rough surface. Now since most of the processes
are mechanized, a motor/lath turning machine is fitted with a sand paper
disc. This disc is in rotation, shell is held in the hand the concave surface/
outer part is moved in an upward direction. This process removes fibers and
any undulations on the shell surface. A skilled careful use of the disc gives the
desired smoothness and neat surface otherwise could lead to thinning of shell.
It is the first stage of the process removes the fiber and exposes the brown
colour of the shell.

The coconut shell after sanding

Sanding Process


Cleaning Process

As the kernel/copra/flesh is removed, the inner surface has to be cleaned and
finished to make it useful. A circular metal brush fitted on to the lathe machine
is used to clean the inner surface of any copra remains and undulations.

The metal cleaning brush

Cleaning Process


Second Sanding

After sanding and cleaning the shell is fairly smooth from the raw material. A
finer sand disc is used to give a further uniform smoothness to the shell. This
process removes any remains of finer fiber, fiber marks, or imperfect ions on
the surface .

The coconut shell after second sanding

Second Sanding Process


Buffing Process

With all imperfection removed, the shell is nearing finish. To give sheen to the
shell, no chemicals or finshes are applied. Instead a disc with cloth edges is
mounted on the machine. When the outer surface of the shell is run against
this disk, a very fine smooth finish, sheen and dark brown colour is achieved.
This is the final process of the coconut shell that gives a finish close as applying
varnish.
Since no chemicals are applied to achieve the finish, the product as soup bowls
and ice cream bowls or cutlery items are completely natural and safe.

The coconut shell after buffing

Buffing process


Cutting Process

There are other products spoons that do not require complete shell. Instead it
is part of the curve is used. This shape of the spoon will have to be cut from the
main shell selecting the particular place of curve. A table mounted saw is used
to cut the shape.

The coconut shell after cutting

cutting Process


Using Spindle

A table mounted rotating axis /spindle is table mounted, this helps to create a
concave shapes on the edges of the shell.

The coconut shell after smoothening the curves

Using the spindle for smoothening the curve’s


Data Collection Bangalore

Bangalore is a metropolitan city, capital of Karnataka. , located almost in the
center of the southern peninsula far way from the coastal regions. Hence there
are rarely any coconut plantations or related industries.
It does not have an history of coconut shell craft practiced in large numbers
before.
RDTDC (regional design and technical development center) provides formal
training for interested personals under nominal fee. Artisan employed with this
center provide the training.
After the formal training there are few persons who have turned to this craft
as their livelihood shifting from other professions . Though run on a small scale,
they bring out different products that are in great demand in the city

Mr .Ravi Shankar in his workshop


Craft Products

Designs created using the hacksaw


Craft Products

Wall clocks made of coconut shell

Ear rings Tic Tak game made of coconut shells


Craft Products

Wine Glasses Bird Pendant Storage bowl


Accessories & jewellery

Current trends and increased customer interest in fashion accessories
specially in a city like Bangalore have led to development of various jewellery
and accessories.

A combination os coconut shell and brass to make a ear ring


Design Development

Various designs are developed by an artist ,keeping in mind the current trends.
Designs are based on the basic geometric forms of rectangle ,circle or triangle.
It is then developed in to complex and intricate designs of birds , fishes , zodiac
signs, spirals, flowers or abstract shapes. These designs range from simple to
intricately detailed shapes.

Detailing on the ear rings


Design Transfer

As these designs are finalised,
A suitable curve on the shell is identified and designs are transferred on to the
outer surface of the shell by either sticking the paper or retracing the design.
The amount of curvature is of prime importance as each designs on different
curvatures will add to the final product of the accessory.

Paper pasted on the coconut shell for cutting


Drilling Hole

Few small holes are drilled with a drilling machine to mark the starting points.
These also points on design where the axe saw blade can pass through from
where the design can be carved out. This avoids cutting the shell from edge
which could is time consuming.

Small holes drilled in the coconut shells


Cutting Design

Few small holes are drilled with a drilling machine to mark the starting points.
These also points on design where the hacksaw blade can pass through from
where the design can be carved out. This avoids cutting the shell from edge
which could is time consuming.

Using a hacksaw to cut the coconut shell


Retail Aspect

Kerala Bangalore
Mr.Sanchu of Jupiter enterprises Bangalore being a metropolitan city,
displays his crafts at exhibitions. lot more awareness and customer’s
These exhibitions create awareness, response towards the crafts.
and generate sales. Pre orders are Chayanisarga being a small unit,
the majority of work. Products are Mr.Ravishankar solely depends on
also manufactured based only on the series of exhibitions.
orders. The Coconut board in Kerala Exhibitions are organized by various
plays a key role in organizing the Non Governmental organizations and
exhibitions and bringing the crafts artist development organizations.
man and customers under one roof. Prices vary according to the different
expenditures of exhibitions, also
includes the profile of the customers.
A temporary stall in a 6 day fare would
results in a price of Rs 150/- for a
pair of earrings. Whereas the same
earrings in another exhibitions that
is spread over a month, more than
temporary stall-stocked earrings that
were priced at Rs100/-.

Mr. Ravishankar at the Dastakari exhibition


Retail Scenario

Bringing coconut craft into the main stream retail market.

Coconut craft though going down to new materials but can be revived back by
possible following strategies.

• Combing the coconut shell with other materials to increase its usage
• Associate the crafts with eco friendly ideology:
• Being a natural product and manufactured with a raw material that is
waste by product. It is well a eco friendly product that is not going to affect
the ozone, reduce the carbon foot print etc
• Develop a range of products that would be used in large numbers. For
example a lighting range of ceiling lights, wall mounted fixtures, table
fixtures could be developed that will give an ethnic and rustic look. It can
be projected for theme restaurants and houses along with scheme of
interiors.
• Range of products that are at hands reach, like office stationary products.
• Promote in areas away from coastal areas.
• Promoting it as an individual brand and not restrict to a handmade craft or
hobby.


New Design Development

As first semester design students we developed few designs from the
understanding that we had from the craft. These designs were developed
over a day which would be ideas that could be further developed into product
ranges that will bring coconut crafts into the retail market.

Initial sketches of the coconut lamp


New Designs

Initial sketches of the coconut lamp Initial sketches of the office stationary


New Designs

Final coconut lamp


New Designs Bibliography

Mr. Chanchu
Jupiter enterprises
Box to store pins
Chertala, Kerala.

Mr .Ravi Shankar
Mobile holder Incense dispenser Chayanisaga
Bangalore

RDTDC
Yeshwantpur
Bangalore

National Institute of Design
Bangalore

Mobile stand
Water dispenser

Design for Retail Experience

72 : Coconut shell Craft

Coconut craft

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