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In all there are about
16 different processes involved in the
manufacturing of Zen Bamboo, the most rigorous
quality checks are made at every stage.
1.Zen Bamboo is
manufactured from mature bamboo canes, which
have at least four years growth and are
selectively harvested from controlled forests.
The Moso bamboo we harvested is well know for
its distinctive feature such as having a
straight main stem, which has little difference
between upper and lower diameter and best for
making bamboo flooring and panels.
2.Bamboo is crosscut to
the required length. The Outside bamboo knots
are ground off.
3.Bamboo is put through
a splitting and sizing machine. The inside
bamboo knots are ground off and outer skin is
4. All the bamboo
strips are then boiled in a bath of boric acid
and lime solution. The purpose of this bath is
to extract the inherent starch that attracts
termites or powder post beetles, Boric acid and
lime are a natural non-toxic repellent and is
used to insure that our products will come to
you best pest free and will continue to be so
throughout the duration of their product life.
5. The strips are put
through a 4 sided planing machine and the strips
are precision milled to a 5 centimeter thickness
to insure an optimum balance of forces in the
6. The next step is to
air dry and then kiln dry the strips to an 8% to
10% moisture level. This takes at least 5 days
and is the single most important process. A
mistake here will result in future product
7. Strips that are to
be carbonized, (which results in a darker color
between caramel and walnut. As bamboo is a
natural product it will result the coloration
after carbonization and the coloration is
permanent and will not fade or sand out.), are
put into a pressurized steam vessel and burned
to achieve this color change.
8.The individual bamboo
strip is carefully checked and assembled by
color for 3 times. We separate light from dark
to minimize color variations in our products.
9.Bamboo strips are
assembled into rough planks by color and put
through a gluing machine.
10.The rough planks are
put into a hydraulic press and set by a
combination of heat and pressure. (We are one of
the very few mills with an 8 foot press capable
of producing 4' by 8' plywood sheets in China
11.The assembled planks
are planed and sanded again on both faces.
12.The side tongue and
groove is now milled into the planks.
13.The planks are
processed through a cutting and shaping machine
where the end tongue and groove is milled.
14.The planks are then
painted on all sides with urethane that provides
for 100% coverage.
15.The board is sanded
and passed through the acrylic urethane roller
application,(six coats),followed by the final UV
curing lights to dry and created an extremely
16.Every board is now
inspected and separated by light and dark
colors, packed and placed into inventory.