Bamboo Harvest: All raw bamboo is obtained directly from the local authorities who manage the forests. Due to the rapid regeneration of bamboo, there is a constant supply of raw material without harm to the ecosystem. The day after cutting the culm, there are up to 7 plants in its place, with no need for replanting, providing erosion control and the other benefits that bamboo forests offer. All bamboo utilized in flooring and panel production is between 5-6 years of age. Proper selection of raw bamboo ensures the high quality product that Bamboo Revolution is known for.
Splitting, Milling, and Boiling: Upon arrival in the factory, the stalks are split into individual strips. These strips are rough milled to remove the green exterior surface, large nodes, and tabasheer. These strips are then boiled in a bath of boric acid and lime solution. This process removes the starch and sugars which attracts termites or powder post beetles, and the solution acts as natural non-toxic repellent for insects and pests alike.
Caramelization and Drying: After completion of the boiling process the strips are either moved to the caramalization chamber or directly to the kiln for dying. If the strips are intended for use in Caramelized (darkening the color) products, the strips are placed in the caramelization chamber and steamed, cooking the sugars, to obtain the rich caramel color. The strips are then kiln dried for more than two weeks. This ensures strict control of moisture content and dimensional stability.
Milling/color matching: Following two weeks of drying, strips are removed from the kiln. The strips are milled to a consistent size with tight tolerances. Then they are strictly color matched and selected for use as horizontal or vertical products. This is the first step that ensures consistent color and a beautiful finished surface of all products.
Lamination: Horizontal flooring is first laminated into stacks of three individual strips. The middle layer is alternated between the hard side (outside edge of stalk) facing up and down. Top and bottom layers always have the hard side of the strip exposed. Five stacks are placed next to each other and laminated together with the orientation of the middle layer alternated. This alternation increases dimensional stability and balances the opposing forces of the top and bottom layers. All flooring uses Dyno brand adhesive. Dyno Adhesive exceeds E1 standards with a near zero formaldehyde content.
Planning/Milling: Planks are then planed, and the tongue and groove are cut lengthwise. The next step cuts the planks to the desired length and the tongue and groove are cut into the ends. The finished planks are then sanded numerous times in preparation for the finishing line. Each milling and sanding machine is an example of the highest technology currently available from Germany and Taiwan.
Lacquer: Ecomax Bamboo proudly applies Treffert coatings from Germany to all pre-finished flooring produced for Bamboo Revolution. Our exclusive process applies 7 layers of lacquer utilizing both ceramics for hardness and aluminum oxide for abrasion resistance. Each layer is UV dried and each plank is sanded three separate times during the coating process. The extensive coating process produces the hardest, most abrasion resistant flooring available on the market today.
Final QC/ Packaging: Each piece of flooring and panels are individually inspected prior to packaging. Only the best material is hand selected to bear the name Bamboo Revolution.