1- LAMINATED BAMBOO PRODUCTS
Material
Laminated bamboo products are made from is made exclusively from the LUONG- Dendrocalamus barbatus Hsueh & D.Z.Li variety which often grows in the Northern areas of Vietnam such as Thanh Hoa, Hoa Binh and Son La Provinces.
This kind of material has big fiber and very strong.
To maximize production capacity and minimize cost, we are buying bamboo panels from our partner suppliers, who can meet various requirements for width and thickness of bamboo.
Panel sanding
Panels are sanded by our 4 big barrel sanding machines to ensure the smooth surface and save time and cost for further production steps.
Cutting
After sanding, panels are cut/ split into small slats/ pieces according to the sizes of baskets. This process can be done by using sawing machines or CNC.
Glueing
Bamboo pieces egdes are pasted with PVA glue for tight bonding.
Assembling
Glued pieces of bamboo are joined together by nail guns. Stainless steel nails are used to make sure the structure is sturdy and prevent rust.
Drying
Unfinished products are dried in the chamber within 2-4 hours to make sure glue and material is dry. This process is powered by 4 automatic drying machines to make sure the moisture is controlled well before painting.
Fine sanding
After the products are dried, they will be sanded by broom sanding machines to remove all splinters and sharp edges while leave smooth surface of product
Painting
Painting is the most important process for making laminated bamboo products.
Only skillful and trained workers are selected to paint products by spraying. We are using painting room with running water to extract and absorb the smell of paint and thus protect workers’ health.
Laminated bamboo products are painted both sides. We use NC paints for most of items and water-based paint for food-contact products.
Laminated bamboo baskets come normally in natural brown color. Various painted colors can also be achieved at customers’ request.
Labeling and packing
Depending on the customer’s request, we can laser burn customers’ logos on the products.
Products can be also stuck with removable stickers at the bottom. Hangtags can also be used to satisfy buyer’s demand,
Products are then classified and wrapped with white wrapping paper or thin foam. Bubble wrapping can be applied for drop test purpose at customer’s request.
For many customers, inner cartons are normally request. We will use reshipable inner to pack goods. Master carton is normally 5 ply which is suitable for sea transportation and transit purpose.
QC guys will follow closely during this process to make sure products OK, no missing or misuse of labels and are packed into correct cartons
Final quality checking
Final quality checking is done 3-5 days before shipment. For each order and shipment shipped out, we will use random checking method by AQL 2.5/4.0 or to customer's standard to identify the quality of the whole lot. If the products are OK, we can ship out; if not the whole lot will be reworked. Hand-out guidelines, quality checklist and approved samples are given to QC staffs to compare and check. Checking records are kept for each order and each shipment.
Warehousing
Packed master cartons are stored in ventilated 2,000 square meter warehouse. The warehouse is divided into sections for different orders and shipments.
2- WOODEN PRODUCTS
Material
We work mostly with acacia in Ha Noi area and rubber in Binh Duong area. We order dimensional pieces of wood at mills. This process may take 2 weeks.
Material will be dried in our drying chambers for 25-30 days to reach 12% moisture.
Planeing
All dried pieces of wood must be planed smooth for better healing while pressing.
Modern 4-side planeing machines are used to secure precise output for wooden slats.
Glueing
Wooden slats then go through glue roller to get even glue on the surface and ready for pressing
Pressing
Wooden slats will be pressed by High Frequency pressing machines. Each time of pressing takes 4 munites including feeding.
Each machine can generate 450 sqm of panels per day
Cutting and assembling
After pressing, panels are cut/ split into small slats/ pieces according to the sizes of products. This process can be done by using sawing machines or CNC.
Small slats are joined together by nail guns and PVA glue. Stainless steel nails are used to make sure the structure is sturdy and prevent rust.
Fine sanding
After the products are dried, they will be sanded by broom sanding machines to remove all splinters and sharp edges while leave smooth surface of product
Painting
Painting is the most important process for making wooden products.
Only skillful and trained workers are selected to paint products by spraying. We are using painting room with running water to extract and absorb the smell of paint and thus protect workers’ health.
Wooden products are painted both sides. We use NC paints for most of items and water-based paint for food-contact products.
Wooden baskets come normally in natural color. Various painted colors can also be achieved at customers’ request.
Labelling and packing
Depending on the customer’s request, we can laser burn customers’ logos on the products.
Products can be also stuck with removable stickers at the bottom. Hangtags can also be used to satisfy buyer’s demand,
Products are then classified and wrapped with white wrapping paper or thin foam. Bubble wrapping can be applied for drop test purpose at customer’s request.
For many customers, inner cartons are normally request. We will use reshipable inner to pack goods. Master carton is normally 5 ply which is suitable for sea transportation and transit purpose.
QC guys will follow closely during this process to make sure products OK, no missing or misuse of labels and are packed into correct cartons
Final inspection
Final quality checking is done 3-5 days before shipment. For each order and shipment shipped out, we will use random checking method by AQL 2.5/4.0 or to customer's standard to identify the quality of the whole lot. If the products are OK, we can ship out; if not the whole lot will be reworked. Hand-out guidelines, quality checklist and approved samples are given to QC staffs to compare and check. Checking records are kept for each order and each shipment.
Warehousing
Packed master cartons are stored in ventilated 2,000 square meter warehouse. The warehouse is divided into sections for different orders and shipments.
3- RATTAN/SEAGRASS/WATER HYACINTH BASKETS
Material
Materials are sourced through our reliable supply chain, from professional material suppliers to ensure quality is good for different customer's requirements.
Rattan, seagrass and water hyacinth are local sources from Vietnam.
Weaving
Our professional weavers are hand-chosen from an elite group within local Red river communities. It is at that time that production plans, specifications and requirements are met for each item(s). With continuous supervision of constant high quality production, any defects discovered are then eliminated.
We use commission- based collectors, who help us to collect semi products/ unfinished products or components from families and bring to our factory for QC and further processing.
Incoming QC
Quality control is the foremost concern of Ngoc Dong. Quality control is maintained on a daily basis and under constant supervision.
At our factory, we do incoming QC for 100% raw products or unfinished products collected from villagers. Approved samples are used by QC staffs to check incoming raw products for sizes, shapes and weaving. Passed pieces will be put into our temporary stock for further processing. Rejected pieces are returned to villagers for fixing. Records are kept for passed and rejected mats for future analysis and improvement.
Color processing
Our color processing is conducted in 2 basic ways:
Processed by hand coloring (staining) is the most convenient way of applying a multitude of colors for our customers. Its advantages include durability and sustained performance over a long period of time.
Dyeing: Dyeing is the key and answer to most challenges of time and labor. Steam is then generated from a heat-feeder for processing, in which, dyes are mixed with water and filtered to remove all foreign matter. Once the foreign matter is completely removed, the residual natural color remains within the boiler for a period of time to sustainment. The advantages of dyeing include numerous colors, minimum time consumption and obviously at the least expense.
Gluing and fixing
The next primary step is glueing and fixing. This is accomplished by a number of employees with one overseen Quality Control Manager. The PVA glue and resin is wholly non-toxic and is applied to strengthen all aspects of hand-woven products. This entire process creates an enormous strong product. Any defect covered by our skilled workers is completely removed from production line.
Drying
For cohesiveness purposes, all products are placed into drying rooms before packing.
Hot and dried air is again applied from drying machines. Each of our large 6 drying rooms can process 1x40 foot containers during any given 10 to 22 hour processing time.
By utilizing several racks during this process, this eliminates any and all product deformation possibility.
Regarding the water content value and humidity levels, it is thoroughly and constantly checked during the entire process, thus providing some of the best products in the world. The moisture level of 12-15% is suitable for all customers in all countries.
Labeling and packing
Any requirement for UPC code labels, Logo identity or other requested attached labels are encouraged and promoted by this firm. In addition, any additional requests for individualized and specialized packaging can, without a doubt, be accomplished by Ngoc Dong.
Woven baskets are normally bulk packed in 5 ply master cartons which are suitable for sea transportation and transit purpose. Customers can also require for inner packing, gift boxes or PDQ trays at their convenience.
QC guys will follow closely during this process to make sure products OK, no missing or misuse of labels and are packed into correct cartons
Final quality checking
Final quality checking is done 3-5 days before shipment. For each order and shipment shipped out, we will use random checking method by SQL2.5/ 4 ( or customer standard, whichever higher) to identify the quality of the whole lot. If the products are OK, we can ship out; if not the whole lot will be reworked. Hand-out guidelines, quality checklist and approved samples are given to QC to compare. Checking records are kept for each order or each shipment
Warehousing
Packed master cartons are stored in ventilated 2,000 square meter warehouse. The warehouse is divided into sections for different orders or shipments.
Export
All goods and products are loaded onto the Ngoc Dong docking facilities into containers and transported directly to Hai Phong Port for onward transportation. For logistic purposes, Hai Phong port is located nearby our facilities.
Any required assistance and or information for routing of shipments will be directly answered by all means necessary.
Although the Ngoc Dong product prices are FOB, CIF quotations may be applied as well. Ngoc Dong will provide any assistance required to obtain the lowest sea freight from local forwarders.
4- SPUN BAMBOO BASKETS
Material
Bamboo is the fastest growing plant and now one of the most eco-friendly materials. In Vietnam, bamboo both grows naturally and is cultivated in highlands and delta areas which is harvested every 3-5 years. There are many varieties of bamboo, most often known are Luong-Dendrocalamus Membraneceus, Buong-Gigantochloa Levis, Tre Gai-Bambusa Bambos, and Nua-Neuhouzeaua.
Spun bamboo is made exclusively from the Nua- Neuhouzeaua Dullooa variety which often grows in the Northern provinces of Vietnam like Thanh Hoa, Ninh Binh, Son La, Yen Bai, Tuyen Quang provinces. This kind of material is soft and easy to bend thus suitable for making baskets.
Bamboo trees are cut at knots and chopped into smaller pieces/bars of 70-80 cm length for easier transportation by qualified suppliers then delivered to us in trucks.
Bamboo then goes into soaking process in water for about 90 days to prevent mold and insects and make it softer. After that, bamboo is removed from water, and left dry in the sun. This treated bamboo will be kept and
used all the year round. This is to ensures that all buyers are provided the most professional and quality products in South East Asia.
Bamboo processing
At families, soaked bamboo pieces are chopped again by hand into smaller slats with width of 1-2 cm for different products. They are then skinned and bended into curved rings by simple machines which carve deep lines in them, allowing for glue to fit in better and make stronger bond.
Molding/ Shape making
Different bamboo slats are dipped into PVA glue, spun by hand into a kind of flat form like mats and fixed by steel outer rings. When these mats are half dried, they are bended with wooden or cement molds to make bowl shapes. These primary molds are then dried in the sun
Planning
The surface of dried molds is very rough so these molds go through planning process, which make it smoother. Skillful workers are used to deliver the smooth surface of all molds. After that these molds are kept at family stock, ready for delivery.
Incoming QC
At our factory, we do incoming QC for 100% molds collected from villagers. Approved samples are used by QC staffs to check incoming molds for smell, shape and sizes. Passed molds will be put into our temporary stock for further processing. Rejected molds are returned to villagers for fixing. Records are kept for passed and rejected molds for future analysis and improvement.
Mold gluing and drying
The first step of finishing molds is gluing. Molds are dipped into water-resistant glue which makes them sturdy and durable. They are then dried in drying chambers for around 4-6 hours at the outcome moisture level of 6-8%. At this moisture level, molds dry well and will crack if the structure is not good or material is too wet. Cracked molds will be sorted out for filling and fixing with a mixture of strong PVA glue and stone powder. This is an important process to make sure that products will not emit humidity and crack again when they come to difficult markets with cold and dry climate.
Filling
At this stage, the surface of molds is still rough and there are many small gaps or holes because bamboo slats dry and condense. We will use filler, a mixture of stone powder and water-resistant glue, to cover the surface of molds and let molds dry again.
Sanding
After the products are filled, they will be sanded by simple machines to make smooth surface and ready for paint application.
Painting
Painting is the most important process for making spun bamboo products. Defects are often found at this stage.
Only skillful and trained workers, who have studied and practiced for 2-3 years, are selected to paint products.. We are using painting rooms with running water to extract and absorb the smell of paint and thus protect workers’ health.
Bamboo bowls are painted both sides. The outside part of bowls is covered with special PU paints and pigments for protecting bowls from scratches and achieve colors requested by buyers. The inside part, which is normally in natural, is painted with water-based paint for food-contact purpose.
There are 3 common kinds of finishing: Transparent or grainy color where bamboo grain exposes and you can see; Solid matte is the color which covers or hides bamboo grain. Solid glossy is like lacquer, delivering a shiny surface while covering bamboo grain.
Labeling and packing
Depending on the customer’s request, we can silk-screen logos of the company on bottom of products.
Products can be also stuck with removable stickers at the bottom. Hangtags can also be used to satisfy buyer’s demand,
Products are then classified and wrapped with white wrapping paper or thin foam. Bubble wrapping can be applied for drop test purpose at customer’s request.
For many customers, inner cartons are normally request. We will use reshipable inner to pack goods. Master carton is normally 5 ply which is suitable for sea transportation and transit purpose.
QC guys will follow closely during this process to make sure products OK, no missing or misuse of labels and are packed into correct cartons
Final quality checking
Final quality checking is done 3-5 days before shipment. For each order and shipment, we will use random checking method by SQL2.4 to identify the quality of the whole lot. If the products are OK, we can ship out; if not then the whole lot will be reworked. Hand-out guidelines or quality checklist and approved samples are given to QC staffs to compare and check. Checking records are kept for each order and each shipment
Warehousing
Packed master cartons are stored in ventilated 2,000 square meter warehouse. The warehouse is divided into sections for different orders and shipments.
Export
All goods and products are loaded onto the Ngoc Dong docking facilities into containers and transported directly to Hai Phong Port for onward transportation. For logistic purposes, Hai Phong port is located nearby our facilities.
Any required assistance and or information for routing of shipments will be directly answered by all means necessary.
Although the Ngoc Dong product prices are FOB, CIF quotations may be applied as well. Ngoc Dong will provide any assistance required to obtain the lowest sea freight from reliable local forwarders.
