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Rattan Production and Quality Controls

Below is a brief story and  explanation of how our products are made and to show the time and care required for each and every item we produce.   We hope the following informatoin creates awareness and appreciation for the amount of work and care that goes into each and every piece that we provide under our Rattan Island and Rattan Home brands. Our products are village crafted products supporting rural communities around 250 Km outside of Yangon in Myanmar (Burma).

Splitting Rattan - Rattan is a solid cane and for crafting our products we use both the inside of the rattan  "The Core" for shaping the stable hardwearing frames and also "the skin" of the rattan is used to weave together the frame tightly.  Firstly, the skin is split from from the rattan core using a maching as pictured below on the left.  This seperates the skin from the core of the rattan in approximate 2-2.2mm strips of skin. The back side of the skin is not smooth for weaving and therefore weavers need to shave the back of the skin to ensure the rattan is flat for smooth weaving when woven to the frame.

splitting machine 1a splitting machine 2a

Framing - The frame of our rattan products is very solid to ensure consistancy of shapes and precise sizes as well as durability.  Our skilled craftsmen create the shape nailing together the rattan cane that forms the structure of our rattan products.

Rattan Weaving -  After a framer has created the first line of the rattan frame our weavers then use a 2mm width of rattan skin weave around the rattan poles and hold together the structure in a strong durable way.   After each pole/layer is woven the girl returns the product back to the framer to add another layer/pole of the frame for the weaver to continue weaving and so on.

Incoming Quality Control - Our products are woven in villages bringing work to around 700 people in the village of Kyi Kyi around 4 hrs drive from Yangon.  After the products are woven they are sent to our factory for quality control, colouring, and export as shown below.  The first part of our QC starts the second the products arrive at the factory where they are checked for correct size, shape and good weaving

Weaving Furniture & Large Items in the Factory - All the furniture items are woven in our factory as it takes great expertise in creating the frame of the rattan products to ensure they are stable and of a high quality for the international export market. Below is a video of two weavers weaving a single sofa.

Sanding - Our finished product has a nice smooth feel to the product.  When the products arrive to our factory the surface of the rattan is quite rugged and therefore we need to smooth the skin by using a soft sandpaper.   A team of around 20 girls ensures the surface is smooth before starting the Quality Control.

Blow torch to remove the loose rattan hair - When the products arrive from the village weavers all the items have small lose rattan hairs.  In order to quickly remove the hairs, the products are blasted quickly with a blow torch to remove the lose hairs.

rattancolor1

Quality Control - We take pride in our high quality.  Many of our QC staff have worked for more than 20 years in the rattan industry since the first baskets were exported from Myanmar.  The QC is a slow process in which any small rattan hairs are removed and any damaged rattan woven skin caused in transport from the village weavers to our factory, needs to be removed and replaced.

 

 

 

 

Colouring - Our colouring actually goes through a number of steps and for different colours there is a slightly different process. Rattan absorbs quite a lot of the colouring material and therefore the first stage of colouring is to saturate and seal the rattan with a polish.  This is brushed on by hand.   Once dried we then can make the colour as shown in the below video before finally sealing the colour with a lacquer to give the products a fresh vibrant shine.

Removing the varnish - To achieve the customers required colours a black paint is used but when it is applied to the rattan it appears brown when removed.

rattancolor7

Final Quality Checking Before Packing - Before packing there is one final check by our experienced managers and staff.  They check the shape, quality of weaving and colour is correct.

Spraying Lacquer - In order to seal the products and to give the products a crisp shinny appearance the final stage of colouring is to seal the products with a varnish.