Production Process

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Vulcabras|azaléia’s process of production of shoes and clothes combines the intensive use of qualified labor and state-of-the art equipment and raw material with constant investments in research and development of new technologies in order to ensure performance, comfort and accessible cost to our products.

Process os Production of Shoes (Sports, Women’s and Professional Boots)

Source: Vulcabras Nordeste S/A – Produção e Desenvolvimento

The manufacture of a shoe is subdivided into many stages according to the extension, diversity of products, size and
structure of the company.

• Conception – At this stage, the shoe is modeled and projected and completely specified. At this stage, science, technology and intense research and development have been increasingly used
to strengthen brands and to differentiate products;

• Cut – made according to the specifications defined in the modeling, employing from knives and hydraulic compressing machines (balance wheel), up to sophisticated equipment of precision cut, such as laser and water jet;

• Backstitch - at this stage, the pieces of the upper are organized, chamfered, folded, cut into small pieces, glued and sewed, usually in a manual process;

• Sewing – The sewing process is used to unite the sole to the upper providing increased security and stability to the shoe;

• Assembly - made almost simultaneously to the cut and sewing, when the heel, sole and insole are glued or sewed. After this stage, the shoes are finalized and packed.

1) Research, Development and Innovation (R,D&I)

Vulcabras|azaleia’s RDI Center, located in Parobé (RS), has over 900 professionals dedicated to this process. It conducts surveys on consumption habits, preferences, trends and development of new technologies in footwear and clothing.

The development of new products or components aligns technical aspects to the needs identified during the survey stages, ensuring by means of quality tests, the preparation of matrixes and moulds that will originate the prototype that will go to the production line. At this phase, the ‘DNA’ of the shoe and clothes are defined.

Once the production process is defined and validated, the components, the assembly phases and inputs to be used are scheduled – list of raw materials, grade of products (size, colors and models), matrix units and other tools required to send the production from the lab to the large scale.

2) Production 

The production line is scheduled according to the specifications
of the product and the equipments are supplied with the
defined raw materials. Cuts are made using computerized systems, hydraulic balance wheels and precision systems.

The soles (rubber, PVC, PU, injected EVA and TPU) are
formulated and mixed, following the specifications of each
type of shoe, and the soles and insoles are prepared using vulcanizing compressing machines (rubber) or injection compressing machines (plastics).

In the backstitch, the components and the superior part of the shoes are united through stitches made by computerized machines or manually.

Finally, the uppers are assembled on the soles using water-based adhesives, solvents or direct injection.

When ready, the shoes are finished, tested and inspected for quality. They are packed and made ready to be shipped and sold.

Sports Clothing Production Process

Source: Vulcabras Nordeste S/A – Produção e Desenvolvimento

The research and development area identifies the principal trends of the station, pursuing new cuts, fabrics, sports technologies, colors, design and fashion trends. Once the principal opportunities are identified, new prototypes are developed or adapted and submitted to tests for verification, visual approval and fit.

Every fabric is submitted to physical lab tests and, once approved, released for production.

When entering into production, the fabrics undergo a loosening process, when they are extended and put to rest for 24 hours in order to prevent shrink after sewing. Plain color fabrics (Cotton or Polyester) are cut in automatic equipment, whereas striped fabrics are manually cut. Then, they are sent to stamping, which may be made through sublimation, ‘transfer’, serigraphy or embroidery.

After this stage, the pieces are sewed and their components are united using computerized or conventional equipment. The finishing involves ironing, revision and labeling of the final product. Finally, the clothes are packed, shipped and sold.