1- 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.
2- PRESSED BAMBOO BASKETS
Material
Pressed bamboo is made exclusively from the Nua- Neuhouzeaua Dullooa variety which often grows in the Northern areas of Vietnam such as Thanh Hoa, Ninh Binh, Son La, Yen Bai, Tuyen Quang Provinces. This kind of material is soft, easy to bend thus suitable for making baskets.
Bamboo trees are cut at knots and chopped into smaller pieces/bars of 70-80 cm for easier transportation by qualified suppliers then delivered to us in trucks.
Mats weaving
At families, bamboo bars are peeled and chopped into thin slats of around 1mm thickness in order to weave nice mats.
The sizes of mats depend on our order and the maximum with is about 1.2 square meter.
Different beautiful patterns can be achieved under skillful hands of weavers. The cost of each pattern depends on the time and skill required to weave.
Incoming QC
At our factory, we do incoming QC for 100% mats collected from villagers. Approved samples are used by QC staffs to check incoming mats for sizes, pattern and thickness. Passed mats will be put into our temporary stock for further processing. Rejected mats are returned to villagers for fixing. Records are kept for passed and rejected mats for future analysis and improvement.
Cleaning
All mats need cleaning to remove tiny bamboo hairs and bamboo odds and ends. Dirty spots are also removed
at this stage. Normally, gas burners are used to make the process faster.
Steaming/ Carbonizing
We are using carbonizers to carbonize/steam bamboo mats. Hot steam from boiler goes into carbonizer to kill all insects inside bamboo materials under 100 degree celsius and high pressure and make bamboo mats softer for perfect bonding.
Gluing and drying
Gluing is the next step of processing the mats. Non toxic glue is used to dip the mats.
Glue must be mixed at suitable formula for each kind of mats and target products, in a way that save glue content and secure bonding of mats when pressing
Mats are then dried whether under the sun or in a drying room with machines at the moisture of about 15-20%
Pressing
Pressing is one of the most important processes for pressed bamboo. We are using 4 hydraulic pressing machines to press mats flat with capacity of 1,000 to 1,500 m2 of mats per day.
Depending on the expected usage of mats, the number of layers of mats for pressing is different. 1-4 layers are for wall decorative panels, 4-6 layers are for baskets and 12-15 layers are for chairs and tables.
Steel molds can be used to press chairs, curved parts of products or cheap 1 layer bowls. In this case, the quantity of order must be big enough to cover the high cost of steel molds.
Time and heat of pressing varies from 10-15 minutes at temperature of 90-120 degree celsius based on numbers and moisture of mats. The outcome of this process is bonded and sturdy mats for next process.
Sawing and assembling
Sawing machines are used to cut mats into smaller pieces with certain sizes to match target products. These bamboo pieces are then assembled into baskets with nailed and PVA glue.
Special wooden molds or fixtures are used to give exact sizes and shapes of all baskets.
For bulky items like storage baskets, laundry hampers and office accessories, we are providing customers with collapsible baskets. In this case, bamboo pieces are drilled and given to our workers to sew with rattan.
Sanding and filling
After the products are assembled, they will be sanded by small machines and by hands to make smooth surface and ready for paint application. All the small holes in the frame( if any), will be filled with stone powder and glue.
Painting
Painting is the most important process for making pressed 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.
Pressed bamboo baskets are painted both sides. The outside part of baskets are covered with special PU paints and pigments for protecting baskets 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.
Pressed bamboo baskets come normally in natural color, carbonized brown color or grainy colors where bamboo grain exposes to you. Washed colors can also be achieved at customers’ request.
Labeling and packing
Depending on the customer’s request, we can silk-screen customers’ logos 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 shipped out, 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 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.
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.
3- RATTAN BASKETS
Material
Bamboo and Rattan are cut and processed right at forest to assure quality control right at the source. Bamboo trees are cut into bars in sizes from 50 cm to 80 cm; they are then skinned and dried. Rattan canes are chopped into from 1.50 m to 2.00 feet lengths.
After the bamboo and rattan are completely processed, it is then suitable for utmost quality processing for all buyers. This is to ensure that all buyers are provided the most professional and quality products in South East Asia.
Weaving
Our professional weavers are hand-chosen from an elite group within the immediate community. 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 have 2 options for customers, bamboo/rattan baskets are made from mixture of bamboo core with rattan strings with lower cost and quality and rattan/rattan baskets are from rattan core and rattan strings weaving with high cost and quality.
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 3 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.
Carbonizing/Steaming: Carbonizing is the most effective way of making colors. Fully trained employees oversee quality control and all aspects to assure even color. These products are then placed into a vat with hot steam applied at high pressure into a heat feeder, and onward to the main boiler.
This process includes removing all starch, sugar and glucose within the bamboo and rattan, thus creating opulent, attractive natural brown color. Its scent and aroma are mutually pleasing.
Gluing and fixing
The next primary step is gluing 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 bamboo and rattan 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 and cartoning.
Hot air is again applied from a heat feeder during the drying process. Each of our large 4 drying rooms can process 2x40 foot containers during any given 8 to 10 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 14-18% 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.
Rattan 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 SQL2.4 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.
