The Engineers’ Association has established a generational mentoring model, including the Junior Engineer Program, to enhance regional scientific and technological awareness and ensure the long-term sustainability of agroforestry knowledge.
For over 26 years of experience, the Association has trained numerous technical experts and developed a successful talent cultivation model in Baisha Village and beyond.
Collaboration with universities and research institutions has strengthened knowledge exchange and capacity building.
The Junior Engineer Program, launched in local schools, fosters early awareness of sustainable forestry, ensuring future generations are equipped with the necessary skills and knowledge.
Human resources are key to the long-term sustainability of agroforestry development.
Research on native species, technical development and standard promotion
The Engineers’ Association prioritises research on native species, leading to breakthroughs in early emergence techniques for bamboo shoots, organic fertiliser production, and mixed planting of hickory and native herbs. These advancements not only address farmers’ technical challenges but also enhance biodiversity and ecosystem resilience. The Association has also contributed to the formulation of forest resource management standards for Lin’an District, ensuring scientific guidance for agroforestry development is rooted in local ecological conditions.
The Association integrates experts from various fields to research native species and develop agroforestry techniques that balance conservation and economic growth
Collaboration with local government, research institutions, and experienced farmers facilitates the development and implementation of scientific standards for local forestry products such as the bamboo shoots, hickory nuts, and other flagship products
Cross-sectoral collaboration is essential for advancing agroforestry technologies and promoting standardised, research-based approaches to native species conservation and sustainable use
Research on native species, technical development and standard promotion
Talent cultivation and inheritance
Organizing field training and exchange activities
Community participation in collaborative development
Trained craftspeople are engaged during their available time.
Lin'an Bureau of Agriculture and Rural Affairs
A network of community partnerships fostered to promote collective growth, with a focus on encouraging female entrepreneurship.
Lin’an has developed a robust network of partnerships, offering one-stop services for organic farming and e-commerce marketing, promoting a culture of collaboration that benefits the entire community.
Female participation in bamboo shoot and hickory nut processing has deep roots in Lin’an. The rise of e-commerce has empowered many women to establish their own brands, leveraging their skills and personal competencies. Supported by government initiatives that encourage female entrepreneurship, a growing number of women are emerging as business leaders in Lin’an, setting an example for others in their communities.
Create effective community cooperation mechanisms to encourage participation in sustainable farming and collaborative production and marketing models.
Use community and e-commerce platforms to facilitate information exchange, improving market transparency and efficiency.
Ecological farming and regional cultural excavation
Promote organic and ecological cultivation, linking eco-tourism and other industries to enhance the cultural value of local agricultural products.
Collaboration with research institutions to offer training and guidance on ecological planting techniques.
Leverage the “celebrity economy” to create flagship products, combining local products like bamboo shoots, hickory nuts, and tea with eco-tourism to add cultural value.
Regular training enhances farmers’ awareness and skills for sustainable planting.
Offer subsidies and rewards to encourage ecological planting practices and reduce chemical inputs.
"Tian Mu Shan Bao", the regional public brand and its sub-brands
Lin'an Bureau of Agriculture and Forestry
The regional public branding helps promote Lin'an's unique agricultural products via e-commerce platforms, build branded products, and enhance product value by setting group standards.
The Lin'an Bureau of Agriculture and Rural Affairs launched the "Tian Mu Shan Bao (Teasures of the Tianmu Mountains)", the regional public brand, strictly reviewing local sustainable sub-brands, ensuring quality and market recognition.
The government supports e-commerce development, builds infrastructure like fresh bamboo shoot markets and logistics bases, and provides training and financial aid.
Use e-commerce data tools to target markets and create a brand that meets consumer demand.
Establish strict quality standards and traceability systems to build consumer trust.
Ecological farming and regional cultural excavation
Community participation in collaborative development
Comprehensive Factory Layout and Workflow of Menstrual Pad Production Unit
Every Side View of factory
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Factory layout with dimension
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Front view of Factory
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Machine Placement in Production Area
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Factory Layout Overview:
The sanitary pad production unit is located near an urban area to ensure easier access to distribution channels, skilled labor, and transport networks. The factory is built with concrete walls and insulated galvanized tin sheet roofing, providing durability and heat protection during warmer seasons.
Total Area: 1,420 sq. ft
Production Scale: Semi-scale
Daily Output: 3,000 pads
Key Areas: Raw material storage, production floor, office, break room, restroom, and an internal lab for testing pads
For visuals of the layout and machine placement, please refer to the gallery attached to this block.
Step-by-Step Production Workflow
Raw Material Collection
Banana Fiber Paper Shredding
Fluffy Absorbent Core Formation
Layer Assembly and UV Sterilization
Packaging and Storage
Note: Hygiene is a top priority. The factory adheres strictly to national hygiene standards and follows clear internal protocols to ensure product safety at every stage of production. For further insights on hygiene practices, see Solution name “Defining a Good Menstrual Pad: A User-Centered R&D Process in Nepal.”
Additional Documents Available in this Block:
Detailed factory layout and production/material flow (PDF)
Energy consumption overview (PDF)
Cost estimation for setting up the factory (PDF)
Access to Skilled and Committed Local Teams: A key enabler was working with a motivated local team of engineers, technicians, and community members who co-developed the layout, machinery, and production processes.
Collaborative Engineering Partnerships: Close collaboration between Sparśa, NIDISI, and Grit Engineering ensured a practical and efficient setup tailored to compostable pad production using banana fiber.
Availability of Local Building Materials: Using locally available materials for construction helped reduce costs, avoid delays, and ensure context-appropriate building design.
Proximity to Urban Infrastructure: Choosing a location close to electricity supply lines, road access, and labor pools helped streamline setup and operational logistics.
Commitment to Hygiene and Quality Standards: The integration of hygiene protocols and on-site testing facilities ensured product safety and regulatory compliance from the beginning.
Hands-On Prototyping and Iteration: The flexibility to prototype machine layouts and factory flow on-site allowed for rapid problem-solving and process improvements.
Start with a Leased Facility When budgets are limited, leasing a space is a more flexible and cost-effective option. Once the product gains traction and operations stabilize, you can invest in building a permanent facility.
Select Your Location Wisely: Choose land with access to government utilities like water and electricity. Avoid polluted areas or sites near chemical factories to meet hygiene standards. Engaging with local community members early can help prevent land-use conflicts later.
Involve Professionals from the Start: Even for small buildings, consulting architects or engineers is essential. Key aspects like ventilation, lighting, and structural durability are often overlooked without expert input.
Maintain Clear Communication with Contractors: Regular updates and site visits help ensure that the work follows your expectations and timeline, reducing delays and misunderstandings.
Plan the Electrical Setup Around Machines: Understand your machines’ power needs (single-phase vs. three-phase) before finalizing layout. Proper planning avoids costly rewiring or power mismatches during installation.
Build Local Technical Support Networks: Having a reliable local metalworker or technician on standby can make a big difference when small repairs or adjustments are needed—keeping your production on track.
Fluffy Absorbent Core Making: Machinery Overview, Detail process explanation, 3D Models
Shredded Banana Paper Feeder Unit
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Fluffy Sheet Forming Unit
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Pneumatic Powered Cutting Unit
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Final Output , Fluffy Absorbent Core
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This block explains how processed banana fiber sheets are transformed into fluffy, absorbent cores using a custom-built semi-automatic machine. These absorbent cores form the middle layer of compostable menstrual pads.
The machine operates through a carefully sequenced, semi-automated process designed to ensure consistent quality and efficiency, especially in low-resource settings:
Shredding: The process begins with a shredder that cuts banana fiber sheets into small, uniform pieces using rotating blades. This ensures consistency for the next stages.
Feeding and Agitation: Shredded paper is fed into a hopper fitted with an Archimedes screw and an agitator. The screw provides a steady feed into the pulverizer, while the agitator prevents clogging.
Pulverizing and Fluff Core Formation: Inside the high-speed pulverizer, the paper is broken down into fine fluff. Centrifugal air motion spreads the fluff evenly onto a confined moving belt.
Compression into Sheets: The evenly distributed fluff is compressed between two belts using a series of rollers. This binds the fluff into continuous absorbent sheets.
Cutting to Size: The sheets are then moved by a conveyor to a cutting unit powered by an air compressor and controlled by a universal timer. This unit cuts the sheet into the required absorbent core dimensions.
Trimming and Fluff Recycling: Dies press the sheet into shape, while surrounding air nozzles blow away excess fluff. This loose material is collected via suction and recycled for reuse.
This process enables clean, efficient, and uniform absorbent core production, using locally available materials and technology appropriate for semi-scale operations.
Additional Resources for Replication:
PDF: Details of Working Mechanism and Operation Procedure
PDF: Electrical Connection Diagram of Cutting System
Strong Collaboration with Local Engineering Workshops Building a custom machine required close cooperation with skilled metalworkers and engineers who could adapt designs, prototype components, and iterate based on field feedback.
Clear Technical Specifications and Planning Developing a detailed understanding of each process step—shredding, feeding, pulverizing, sheet formation, and cutting—was essential for translating needs into machine design.
Availability of Banana Fiber Paper A consistent and quality supply of processed banana fiber sheets was necessary to ensure the performance of the machine and the fluff core output.
Reliable Power Supply and Air Compression System The machine requires stable electricity (including high-speed motors) and a safe, well-regulated compressed air system for the cutting unit and fluff recycling.
Prototyping Mindset and Flexibility The development process included trial-and-error phases, requiring patience, a flexible approach to adjustments, and ongoing testing to achieve the desired fluff consistency and hygiene standards.
Set Clear Agreements with Machine Builders: A well-defined contract is essential. It should cover machine capabilities, materials to be used, budget constraints, delivery timelines, mechanisms for addressing delays, and any expected custom modifications.
Maintain Frequent Communication and Site Visits: Regular check-ins with the fabrication team—both virtual and in-person—help ensure the machine is built as per design, and enable fast troubleshooting when issues arise.
Expect Delays and Use Time Strategically: Machine fabrication often takes longer than anticipated. During such delays, focus on parallel tasks like training, raw material procurement, or factory setup to avoid bottlenecks later.
Technical Lessons from Using the Custom Machine
Air-Compressed Cutting System: A Safety Concern: The air-compressed cutting mechanism proved complex and posed safety risks due to potential pipe disconnections under high pressure. A roller-based cutting system would be simpler and safer for future designs.
Dust Management is Critical: Banana fiber, when pulverized, creates fine airborne particles. Combined with high-pressure air, this generates a lot of dust. Effective ventilation and dust control systems are essential for safe, hygienic operation.
Custom Machine Development Requires Patience: While tailored machines offer precision and innovation, the design process demands strong technical understanding, problem-solving, and patience through trial-and-error development cycles.
