Capacity
Capacity in use and production lines
The capacity figure is the capacity currently in use, not a maximum.
- Pairs per month, capacity in use
- 300,000
- Sewing lines
- 40
- Vulcanized assembly lines
- 6
- Cementing assembly lines
- 2
- Finishing lines
- 5
Production flow
From raw material to finished shoe
Stages follow the actual production flow. Each one lists its machines and lines as they stand.
Stage 01
Rubber / Foxing
Rubber is processed in-house: mixed into compound, milled, calendered into sheets, and extruded into foxing, the rubber tape that wraps the sidewall of a vulcanized shoe.
- 4 kneader machines
- 7 rubber mixing mills
- 5 calendar machines
- 6 foxing extruders
Stage 02
Cutting
Upper materials are laminated, cut into components, and skived at the edges so they stitch cleanly.
- 32 hydraulic cutting machines
- 3 laminating machines
- 10 skiving machines
Stage 03
Sewing
Components are stitched into complete uppers. Programmed stitch patterns run on computer stitching machines.
- 40 sewing lines
- 18 computer stitching machines
Stage 04
Eyelet
Eyelets are set into the uppers. Eyelets are among the components we make ourselves.
- 42 eyelet machines
Stage 05
Outsole Press
Rubber outsoles are moulded on hydraulic hot presses, then ground and buffed so the surface is ready for bonding.
- 6 hydraulic rubber sole hot presses (96 holes)
- 12 grinding/buffing machines
Stage 06
Assembling
Uppers, soles, and foxing are assembled into shoes. Vulcanized models are cured in vulcanizing tanks (autoclaves) so the rubber bonds to the upper; cemented models are bonded on separate lines.
- 6 vulcanizing tanks/autoclaves
- 6 vulcanized lines
- 2 cementing lines
Stage 07
Finishing / Packing
Shoes are finished, laced, and boxed pair by pair before going to the warehouse.
- 5 finishing lines
On the production floor
See the machines at work
Short clips from our lines. Choose a stage name to see its machine list.
01CuttingA cutting die stamps components from the sheet 02Computer stitchingA programmed stitch pattern 03SewingThe label is stitched to the upper 04AssemblingThe upper is shaped over the last 05FinishingLaces go in pair by pair 06Ready to packFinished pairs wait to be packed
Vertical integration
We make the key components ourselves
We process our own rubber and make our own laces, soles, uppers, and eyelets.
- Rubber compound and foxing
- Soles
- Uppers
- Laces
- Eyelets
For partners
What integration means for you
Quality control
Key components are made under the same working standards, so a quality issue can be traced back to the stage it came from.
Schedule control
Fewer dependencies on outside component suppliers make production schedules easier to control.
Cost control
In-house components carry no intermediary supplier margin, and specification changes are handled on our own lines.
Cooperation
Discuss a production requirement
For questions about our production capabilities and possible cooperation.