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The bamboo forests in China have largely been cultivated there for many hundreds, and in some cases thousands, of years. Every year, in spring and summer, new poles (called culms), grow from a shoot underground. One shoot of the larger timber varieties of bamboo weighs between 2-4 kg when it is less than 30cm high. At this stage it is quite soft and can easily be cut with a knife. It is also eminently edible, when prepared properly. If left to grow, this shoot reaches its full height of say 20 metres in an incredible 3 months, (height depending on variety). When mature, the timber is extraordinarily resilient and strong. It has a tensile strength quite similar to mild steel.
Bamboo textile fibre is made from bamboo timber which has matured in the forest for at least 4 years. Even in remote areas of China bamboo forests are highly valued and carefully tended and managed. In summer, when new shoots reach their full height, they are marked with a year code which makes sure they are harvested at the right maturity. When harvested they are taken to mills where they are crushed and submersed in a strong solution of sodium hydroxide which dissolves the bamboo cellulose. With the addition of carbon disulfide it renders the mix ready to regenerate fibres which are then drawn off, washed and bleached to a bright white colour and dried. The resultant fluff is very long in staple and visibly finer than other fibres. Then they are spun into yarn, like any other textile fibre. The longer staple and higher tensile strength is what makes a tough, soft yarn – which is not as susceptible to wearing and fraying as many other yarns. This is what gives bamboo fabrics excellent durability. The hollowness of the fibre contributes to its very high level of absorbency. But it also takes longer to dry on a clothesline. The hollowness of the fibre also enables it to hold dyes and pigments more readily and permanently, thus making it much more colourfast.
The two main chemicals used in the process are sodium hydroxide and carbon disufide.
It was only discovered that carbon disulfide was a nerve poison after many years of exposure at high concentrations by factory workers in Italy in the 1930s and 40s. With adequate ventilation it is not a problem these days and it breaks down when in contact with the natural elements. Neither carbon nor sulfur are poisonous elements.
Sodium hydroxide is also known as caustic soda, and it is true that it is strongly alkaline and will react with many substances. However, it is not toxic at all and is used extensively in cooking. Used in quite high concentrations it is what gives traditional pretzels their distinctive flavour.
We have produced a video to give you a fair idea of how bamboo fibre, or bamboo rayon is made.
The demonstration shows not exactly how it is made commercially, because that takes much more time, but the principles are much the same.
We have named the video “Kitchen Chemistry” because the substances involved are almost as tame as those used in everyday kitchens and households.
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 want to learn more, please visit our website bamboo products processing equipment factory.