Our laminated bamboo products are crafted exclusively from the LUONG bamboo, scientifically known as Dendrocalamus barbatus Hsueh & D.Z.Li, which thrives in the northern regions of Vietnam, including Thanh Hoa, Hoa Binh, and Son La provinces. This bamboo variety is renowned for its robust fibers and exceptional strength. To optimize production efficiency and reduce costs, we source bamboo panels from trusted partner suppliers who provide panels with the required width and thickness specifications.
The bamboo panels undergo a sanding process using our four large barrel sanding machines. This step ensures a smooth surface, streamlining subsequent production stages while saving both time and costs.
Once sanded, the panels are cut into smaller slats or pieces according to the basket sizes. This precision cutting is carried out using either sawing machines or CNC technology.
The edges of the bamboo pieces are bonded with PVA glue, ensuring a tight and durable connection.
The glued bamboo pieces are assembled using nail guns, with stainless steel nails chosen for their durability and resistance to rust, ensuring a sturdy structure.
The assembled, unfinished products are dried in a controlled chamber for 2-4 hours. This drying process, powered by four automatic machines, ensures that both the glue and material are thoroughly dried, effectively controlling moisture levels before painting.
After drying, the products are finely sanded using broom sanding machines. This step removes any splinters and sharp edges, leaving the surface smooth and ready for the next stage.
Painting is a crucial step in the production of laminated bamboo products. Only skilled and trained workers are selected to paint the products using spray techniques. The painting is conducted in a specialized room with running water to extract and absorb paint fumes, thereby protecting the health of our workers. The products are painted on both sides, with NC paints used for most items and water-based paints applied to products intended for food contact. While the natural brown color of laminated bamboo is common, we can achieve various other colors based on customer requests.
Depending on customer requirements, we can laser engrave logos onto the products. Alternatively, removable stickers or hangtags can be applied as per buyer specifications. The products are then classified and wrapped in white paper or thin foam, with bubble wrap used for items requiring drop-test protection. Inner cartons are often requested by customers, and we utilize reshippable inners for packing goods. The master cartons are typically 5-ply, making them suitable for sea transportation and transit. Our QC team closely monitors this process to ensure correct labeling and packing.
Final quality checks are conducted 3-5 days before shipment. For each order, we use random sampling methods, following the AQL 2.5/4.0 standard or specific customer standards to assess the overall quality. If the products meet the required standards, they are cleared for shipment. If not, the entire lot undergoes rework. QC staff are provided with guidelines, quality checklists, and approved samples for comparison during this process, with records maintained for each order and shipment.
The packed master cartons are stored in our 2,000 square meter ventilated warehouse. The warehouse is systematically divided into sections to manage different orders and shipments, ensuring efficient organization and easy access.
Our wooden products are primarily crafted from acacia wood, sourced from the Ha Noi area, and rubberwood from the Binh Duong area. We procure dimensional pieces of wood directly from mills, a process that typically takes about two weeks. Upon arrival, the wood undergoes a drying process in our chambers for 25-30 days to achieve an optimal moisture content of 12%.
Once dried, the wood pieces are smoothed through a planing process, which is essential for ensuring a seamless bond during pressing. We use modern four-side planing machines to deliver precise, smooth wooden slats.
The wooden slats are then passed through a glue roller, which applies an even layer of glue to their surfaces, preparing them for pressing.
The glued wooden slats are pressed using High-Frequency pressing machines. Each pressing cycle takes about four minutes, including the feeding time, with each machine capable of producing 450 square meters of panels per day.
Following pressing, the panels are cut into smaller slats or pieces according to the product specifications. This cutting process is performed using sawing machines or CNC technology. The smaller slats are then assembled using nail guns and PVA glue. Stainless steel nails are utilized to ensure a sturdy, rust-resistant structure.
After assembly, the products are finely sanded using broom sanding machines to remove any splinters or sharp edges, resulting in a smooth finish.
Painting is a critical step in the production of wooden products. We select only skilled and trained workers to handle the painting process, which is done through spraying in a specialized room equipped with running water to extract and absorb paint fumes, thereby safeguarding workers’ health. The wooden products are painted on both sides, typically with NC paints for most items, and water-based paints for products intended for food contact. While natural wood color is common, we offer a variety of painted finishes to meet customer requests.
Depending on customer requirements, we can laser-engrave logos onto the products or apply removable stickers at the bottom. Hangtags can also be attached to satisfy specific buyer demands. The products are then classified and wrapped in white wrapping paper or thin foam, with bubble wrap available for items that require drop-test protection. For many customers, we use reshippable inner cartons for packing, and the master cartons, typically 5-ply, are designed for durability during sea transportation and transit. Our QC team closely monitors this process to ensure accurate labeling and packing.
Final quality checks are conducted 3-5 days before shipment. We employ a random sampling method, following the AQL 2.5/4.0 standard or specific customer standards, to assess the overall quality of the lot. If the products meet the required standards, they are cleared for shipment. If not, the entire lot is reworked. QC staff are provided with guidelines, quality checklists, and approved samples for comparison during this process, with detailed records maintained for each order and shipment.
The packed master cartons are stored in our 2,000 square meter ventilated warehouse. The warehouse is systematically divided into sections to manage different orders and shipments, ensuring efficient organization and easy access.
At Ngoc Dong, we meticulously source our materials through a trusted supply chain to ensure they meet various customer requirements. Our rattan, seagrass, and water hyacinth are locally sourced from Vietnam, guaranteeing high-quality raw materials for our woven products.
Our weaving process involves a team of elite weavers selected from the Red River communities. Each production plan, specification, and requirement is meticulously addressed to ensure top-quality output. Continuous supervision ensures that any defects are promptly identified and corrected. We also employ commission-based collectors who gather semi-finished products and components from local families, bringing them to our factory for quality control and further processing.
Quality control is a cornerstone of our operations. We conduct rigorous incoming QC on 100% of the raw and unfinished products collected from villagers. QC staff use approved samples to inspect the sizes, shapes, and weaving quality of the incoming materials. Approved items are stored temporarily for further processing, while rejected items are returned to the villagers for correction. Detailed records of passed and rejected items are maintained for ongoing analysis and improvement.
Our color processing is performed in two primary ways:
The gluing and fixing stage involves applying non-toxic PVA glue and resin to strengthen the hand-woven products. Overseen by a Quality Control Manager, this process ensures that all defects are eliminated, resulting in a robust final product.
To ensure product cohesion, all items are placed in drying rooms before packing. Our six large drying rooms, each capable of processing a 40-foot container in 10 to 22 hours, use hot, dry air to prevent deformation. We constantly monitor water content and humidity levels to maintain a moisture level of 12-15%, ensuring top-quality products suitable for global markets.
We accommodate various customer requirements for labeling, including UPC codes, logos, and other custom labels. Additionally, we offer specialized packaging options such as inner packing, gift boxes, or PDQ trays. Woven baskets are typically bulk-packed in 5-ply master cartons, ideal for sea transportation and transit. Our QC team ensures that products are correctly labeled and packed in the appropriate cartons.
Final quality checks are performed 3-5 days before shipment using a random sampling method according to SQL2.5/4.0 standards or higher customer standards. If the products pass, they are cleared for shipment; otherwise, the entire lot is reworked. QC staff are provided with guidelines, checklists, and approved samples for accurate comparison. Detailed records are maintained for each order and shipment.
Packed master cartons are stored in our 2,000 square meter ventilated warehouse, which is organized into sections for different orders and shipments to ensure efficient management and access.
Goods are loaded onto containers at our docking facilities and transported directly to Hai Phong Port for onward shipping. Located nearby, Hai Phong Port facilitates efficient logistics. We offer assistance with routing and provide FOB and CIF quotations. Ngoc Dong also supports efforts to secure the lowest sea freight rates from local forwarders.
Bamboo, renowned for its rapid growth and eco-friendly qualities, is a vital material for our products. In Vietnam, bamboo is both naturally occurring and cultivated in highland and delta regions, with harvests every 3-5 years. We use several bamboo varieties, including Luong-Dendrocalamus Membraneceus, Buong-Gigantochloa Levis, Tre Gai-Bambusa Bambos, and Nua-Neuhouzeaua. Our spun bamboo comes exclusively from the Nua-Neuhouzeaua Dullooa variety, grown in Northern provinces like Thanh Hoa, Ninh Binh, and Son La. This variety is valued for its softness and flexibility, making it ideal for basket weaving.
Bamboo trees are harvested, cut into 70-80 cm lengths, and transported by qualified suppliers. To prevent mold and insects and to soften the bamboo, it undergoes a soaking process in water for about 90 days. After soaking, the bamboo is sun-dried and stored for year-round use, ensuring we deliver consistently high-quality products.
In local families, soaked bamboo is hand-chopped into smaller slats, typically 1-2 cm wide. These slats are skinned and bent into curved rings using simple machines that carve deep lines, allowing for a stronger bond with glue.
Bamboo slats are dipped into PVA glue and spun by hand into flat forms, like mats, which are then secured with steel outer rings. Once half-dried, these mats are shaped into bowls using wooden or cement molds. The primary molds are then dried in the sun.
The surface of dried molds is often rough, so they undergo a planing process to achieve a smooth finish. Skilled workers ensure that each mold is finely finished before being stored and prepared for delivery.
At our factory, we conduct stringent incoming QC on 100% of molds collected from villagers. QC staff use approved samples to inspect molds for smell, shape, and size. Approved molds are stored temporarily for further processing, while rejected ones are returned for correction. Detailed records of passed and rejected molds are maintained for continuous improvement.
The gluing process involves dipping molds into water-resistant glue, enhancing their durability. The molds are then dried in chambers for 4-6 hours, achieving a moisture level of 6-8%. This ensures that the molds do not crack due to excessive moisture or poor structure. Cracked molds are repaired using a mixture of PVA glue and stone powder to prevent future issues in cold and dry climates.
To address any gaps or holes in the rough surfaces of the molds, we apply a filler mixture of stone powder and water-resistant glue. This ensures a smooth surface, which is then allowed to dry before the final sanding.
Once filled, molds are sanded using simple machines to achieve a smooth surface, making them ready for painting.
Painting is a crucial stage in the production of spun bamboo products. Only highly skilled and trained workers, who have undergone 2-3 years of training, handle this process. We use painting rooms with running water to absorb paint fumes, protecting worker health. Bamboo bowls are painted on both sides, with the exterior coated in special PU paints and pigments for scratch resistance and color customization, while the interior is painted with water-based paint for food safety. We offer various finishes: Transparent or grainy colors that showcase the bamboo grain, Solid matte that hides the grain, and Solid glossy for a lacquer-like shine.
We accommodate various labeling requests, including silk-screened logos, removable stickers, and hangtags. Products are classified and wrapped in white wrapping paper or thin foam, with bubble wrap available for drop-test protection. Inner cartons, gift boxes, and PDQ trays can be provided as requested. Woven baskets are bulk-packed in 5-ply master cartons, suitable for sea transport. QC staff ensure correct labeling and packing.
Final quality checks are conducted 3-5 days before shipment. We use random sampling methods, following SQL2.4 standards or higher customer standards, to assess the quality of each lot. Approved products are shipped, while non-compliant ones are reworked. QC staff are provided with guidelines, checklists, and approved samples for accurate comparison, with detailed records kept for each order and shipment.
Packed master cartons are stored in our 2,000 square meter ventilated warehouse, organized into sections for different orders and shipments to ensure efficient management and access.
Goods are loaded onto containers at our docking facilities and transported directly to Hai Phong Port for onward shipping. Hai Phong Port's proximity to our facilities facilitates efficient logistics. We provide assistance with routing and offer FOB and CIF quotations. Ngoc Dong also helps secure the lowest sea freight rates from reliable local forwarders.
