Technology of bamboo production

The bamboo stems are marked early for the right harvest time, 
Photo: Guillaume Bonnefont by Moso International B.V.

Harvesting the right bamboo

Endless bamboo forests grow in the mountains to the east of China. The bamboo stems must not be too old to be processed into the high-quality MOSO bamboo products; ideally they are harvested when they are five years old. Younger stems are not yet completely woody, while older ones turn grey and brittle. The very best raw material is the prerequisite for the very best end product. The quality of the bamboo stems can be partly assessed at the time of purchase, but is difficult to recognise in the new end product. However, the quality of the bamboo raw material can still - unexpectedly - come to light later.

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Sorting of the split lamellas
Photo: Guillaume Bonnefont by Moso International B.V.

Manufacture of bamboo strips from hollow tubes

The freshly harvested bamboo stems are split lengthwise into strips. This step of the production process goes beyond the mere splitting of the hollow bamboo tube. The inner and outer bark must also be removed so that the surface is optimally prepared for gluing. The higher the quality of the bamboo strips, the more waste is produced, as more bamboo has to be peeled off the slats to ensure that there is really no bark left. You can judge the quality of the strips when you buy them, but you won't see the difference in the end product at first glance. MOSO only accepts the very best strips for its bamboo products.

Splitting of the lamellas into fine strips
Photo: Guillaume Bonnefont by Moso International B.V.

Crushing of the slats for further bamboo production

The bamboo strips are then cut into millimetre-thin strips and prepared for further processing. The quality of this step plays a decisive role for the quality of the binder impregnation and gluing in the next production steps. If the strips are to be better refined, this requires more precise handling and thus higher costs.

After the thermal treatment the colour of the bamboo product changes. 
Photo: Guillaume Bonnefont by Moso International B.V.

Thermal treatment for adjustment of stability and colour

Most bamboo products are available in three standard colours: natural, caramel and chocolate. Natural colour is the natural material colour, without any treatment. When the bamboo strips are steamed, they turn brown: caramel. And after a thermal treatment at approx. 200 °C their colour changes to a dark brown: Chocolate. This treatment also changes the material: the sugar component of the bamboo is broken down, making the material more durable and stable. This treatment can be carried out at different temperatures and for different periods of time. Some manufacturers prefer lower temperatures and shorter treatment times due to lower costs. MOSO always focuses on the optimal durability and stability of the final bamboo product.

Dynea produces high quality resins

Bamboo products contain bamboo and binders

The finely cut bamboo strips are impregnated with a binding agent to connect the bamboo strips and are highly compacted. MOSO aims to replace the chemical resins with biological binders. However, because the quality of the end products has the highest priority for MOSO, this is not yet possible. To this day, no bio-binder can meet the high requirements for the manufacture of top-class products. Until such time as organic binders can be used in production without impairing quality, binders of well-known brands will be used. This ensures that emissions are kept to a minimum.

It is very difficult to determine the type and quantity of binder used once the end product has been manufactured. Nevertheless, this is one of the most important differences between density and strand woven bamboo products. Binder costs have a significant impact on total production costs. For cost reasons, many plants produce with their own binders or use binders from local manufacturers, while MOSO consciously chooses to process well-known branded products such as Dynea.

Compaction of the bamboo material

There are various methods for compressing bamboo

Depending on the type of product, the dimensions and the required bamboo colour, compression (compaction) can be carried out using cold or hot pressing systems. Each binder needs a certain temperature for hardening during compression. In addition, the way in which the fine bamboo strips are inserted into the moulds influences both the stability and the appearance of the final product. After this important production step, the material is first tested by trained MOSO quality inspectors to ensure the quality of the final product. By the way, it is practically impossible to test this without laboratory testing.

Quality control by MOSO inspectors

The moisture content defines the stability of bamboo products

Like all other natural materials, bamboo is sensitive to moisture: it swells with increasing moisture content and shrinks with decreasing moisture content. It is crucial that the moisture content is reduced and controlled in all production steps in drying chambers. The moisture content of the final product supplied by the manufacturing plant has a decisive influence on the technical behaviour of the bamboo products after installation. A higher moisture content of the product usually leads to more problems with moisture fluctuations later on.

Since strand woven or density bamboo products are extremely dense and hard, it is difficult to determine the moisture content of the final product. Only through our continuous product development over the last 10 years has MOSO been able to define the method for controlling the moisture content of each end product. To ensure the high quality of bamboo products in their final application, local MOSO quality inspectors monitor the moisture content of each production batch during and after production.

Final density production

Final Density Bamboo Product

The final step in the production of density bamboo is the final profiling of the material. A material as hard and dense as Density Bamboo places the highest demands on the tools used for profiling. MOSO guarantees the correct processing of the material into end products by using high-quality plant technology, often from European manufacturers. A good example of this is the way in which the profiles for click systems are cut into the material. The best machines also enable the best finishing of the surfaces. Depending on the product, MOSO uses Density Bamboo as a top layer for panels and floor coverings or as solid beams or floor coverings.

If you&#;re already one of our wonderful Pure Zone customers, you&#;ll know how much we adore Bamboo for the multitude of benefits it offers. It&#;s what we&#;ve become known for! As one of the most versatile and sustainable resources on the planet, Bamboo has captured the imagination of artisans, designers, and eco-conscious individuals alike. 

We often get asked about how our products are made - so let's take a closer look at the Bamboo fibre manufacturing process from its origin in serene Bamboo groves to its place in our homes. It&#;s a journey that is a testament to sustainable practices and the harmonious connection between the environment and our daily lives and we are excited to share it with you!

(Pictured here is our stunningly soft Linen Bamboo Quilt Cover Set in White. Available in six tonal shades.)

HARVESTING 

The harvesting process of Bamboo requires careful timing, expertise, and a commitment to chemical-free practices. When the Bamboo reaches its optimal maturity at around 3-4 years old depending on the species, it is meticulously selected for harvest. What sets Bamboo apart is its natural resistance to pests, eliminating the need for chemical pesticides or herbicides during its growth. This also extends to the harvesting process as well, ensuring the Bamboo retains its organic, chemical-free nature.

EXTRACTION OF THE BAMBOO FIBRES

After the bamboo is harvested, it undergoes a thorough cleaning to remove any impurities. The next step involves breaking down the Bamboo stalks into smaller pieces, before being treated with natural enzymes. This natural fermentation process softens the plant's inner fibres, making them easier to extract. This results in high-quality bamboo fibres that can be spun into yarn and woven into bedlinen and other textiles.

SPINNING

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Following the extraction, the bamboo fibres are spun together to form yarn. The spun bamboo yarn possesses inherent qualities such as breathability, softness, and moisture-wicking abilities, making it a sought-after choice for eco-conscious home products. 

WEAVING

At Pure Zone, the Bamboo fibres are transformed into luxurious bedlinen using a twill weaving technique to provide added strength to the fabric. This method creates a diagonal ribbing effect, resulting in a silky smooth finish, enhancing both durability and drape. 

DYEING AND FINISHING

We&#;re almost there - at this stage Bamboo textiles come alive with vibrant colours through a dyeing process that leverages Bamboo's absorbent nature for long lasting colour. It&#;s at this time at Pure Zone we choose to use natural dyeing methods to enhance the fabric without using harsh dyes or chemicals. Explore our Activated Charcoal Bamboo range which uses the natural pigment from Activated Charcoal here. 

CUTTING AND SEWING

Artisans then carefully trim the fabric to exact measurements before skilled seamstresses stitch them together, crafting everything from sheets to pillowcases, quilt covers, towels and robes. This stage combines creativity and precision, highlighting both the quality of Bamboo fabrics and the skill of those who work with them.

QUALITY CONTROL

The finished Bamboo bedlinen goes through rigorous quality checks to ensure it meets the desired standards. This involves checking the overall quality and more specifically the quality of the stitching. Bamboo fibre is so soft, this step is particularly important to ensure the stitching has been lined up correctly and sewn without any movement.

PACKING AND DISTRIBUTION

Once everything is approved, the Bamboo bedlinen is neatly folded, packaged in thoughtfully designed self-fabric pouches (no plastic here), and prepared for distribution to our Melbourne Warehouse where it&#;s shipped directly to our Pure Zone customers ready for their best sleep ever.

TIME TO GET COSY

Wrapping up our journey through the Bamboo manufacturing process, from the Bamboo groves where it all begins, to the moment these fibres find their cosy spot in our homes, it's a tale of innovation, sustainability, and a little bit of magic. So next time you snuggle up in your Bamboo bedlinen, remember you're not just cosying up to sheets &#; you're embracing a story that's woven with eco-friendly threads and a whole lot of love along the way.

Explore our Bamboo range or read a little more in Bamboo and sustainability here.

If you are looking for more details, kindly visit ODM bamboo products manufacturing machine.