Production Process with Vietnam Rattan Baskets

Vietnam Rattan Baskets are popular products, NAPI would like to show to customer production process of them as following:

Material

The 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 NAPI. 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 2×40 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 NAPI.

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 1,500 square meter warehouse. The warehouse is divided into sections for different orders and shipments.

Export

All goods and products are loaded onto the NAPI 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 NAPI product prices are FOB, CIF quotations may be applied as well. NAPI will provide any assistance required to obtain the lowest sea freight from local forwarders.

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