Fresh cut monkey pod wood tree limbs ready for rough cut and carving.
Carvers work with simple hand tools by eye and are trained by each other
All products are processed in stages by trained teams
The hand carved products are brought to a solar oven, where they're brought down to below 30% MC (moisture content) as measured with non-invasive and invasive Delmhorst wood lumber meters.
In Stage Two, the items are put into propane fired kilns where they're brought down in stages at varying temperatures to 20% MC and then again to below 10% MC.After this, we continue with Stage Two by raising the temperature high enough (80°-90°C or 176°-194°F) to insure that there are no parasites in the wood. Because most hand carved wood products are varying wall thicknesses which makes drying difficult, we “lose” a percentage of products in the process. However, we're willing to do this to ensure a perfectly clean and sanitary wood piece, and we also use the "lost" wood for repairs so as not to waste anything.
During Stage Three, we sand the product to smooth the rough carving into the desired shape. This is all done by eye so every piece is unique, sizes are not exact, and products are not perfectly square. The beauty of the completely unique piece can be seen at this time!
Fourth stage is repairing the checking (cracks) that have been uncovered by the sanding or caused by the drying process. We use teak sawdust and hot glue to seal the cracks and smooth the surface.
Stage Five is where we complete the finishing process and put each piece through a complete Quality Control check.
Propane fired wood kilns being loaded with product separated by dried stringers.