Production at scale.
Your approved sample, made in volume. AI-assisted material planning, dieless cutting and automatic stitching work alongside experienced operators and specialist equipment.
Technology
Technology that protects
your calendar.
Where our investment shows in your order: accurate components, consistent seams and a delivery date kept in view.
01AI-assisted nestingComponents nested across each hide before it is cut, for efficient use of your leather.
02Dieless cuttingUpper and lining components cut straight from digital patterns, true to your approved sample.
03Automatic stitchingProgrammed seams on the upper, repeated pair after pair through your order.
04Production monitoringOutput and downtime in view, so your delivery date stays in sight.Ten departments
Every department answers
to your order.
From the leather store to the packing line, your approved sample’s requirements carry through each department.
01General store & leather storeYour materials organised for the departments that use them.
02Cutting & advanced cuttingDigital patterns, AI-assisted nesting and dieless cutting.
03PreparationMarked, punched, checked and skived before assembly.
04DecorationMulticolour embroidery from computerised multi-head machines.
05Closing & advanced closingComplex seams and demanding materials, stitched with repeatable detail.
06Upper passingUppers reviewed against your approved product before lasting.
07Lasting preparationUppers pre-formed and moulded to the shape of the last.
08LastingUppers lasted and soles attached, with soles from the AFPL Sole Unit.
09FinishingShape, surface and detail brought to the finish you approved.
10PackingPacked to your branding and packaging specification.The full equipment listFor technical teams
| Department | Equipment and operations |
|---|---|
| General store & leather store | Leather handling and storage; organised storage for other production inputs |
| Cutting & advanced cutting | CAD/CAM patterns; AI-assisted nesting and material planning; dieless cutting; auto marking |
| Preparation | Automatic UV marking; punching machines; vamp checking machines; skiving equipment |
| Decoration | Computerised multi-head embroidery |
| Closing & advanced closing | Automatic stitching; computerised stitching heads; needle switching on the pattern tacker; Strobel machines; seam-sealing machines for waterproof footwear; welding machines; riveting and eyeleting |
| Upper passing | Review of stitching, component alignment and surface appearance |
| Lasting preparation | Moccasin pre-forming; 3D crimping; upper shaping; toe and counter moulding |
| Lasting | Toe and counter moulding; toe-lasting equipment; factory lacing machinery; welt-attaching plants; sole stitching, heel nailing, rough rounding, rolling and trimming |
| Finishing | Heat setting and boot-leg ironing; automatic infrared tunnels; UV and spray antifungal treatment; embossing for branding on completed footwear; hand finishing where the product requires it |
| Packing | Presentation, quantities and order identification checked for dispatch |
On film
From first cut
to finished pair.
Filmed on our own production floor.
By construction
Set up around
the specification.
Five upper and six bottom constructions, each with its own sequence on the floor, from the upper to the finished pair.
All constructionsUpper constructions
Strobel machinesStrobelThe upper stitched to a flexible insole around its edge.Lasting and mouldingStuck-onUppers lasted and prepared for a bonded sole.Seam-sealing machinesWaterproofSuitable materials and linings, with seams sealed on the line.Closing and seam workBootieA specialist inner assembly, developed around the upper, the fit and water protection.Dial closureAuto-lacingA dial-operated closure, with cable routing built into the upper.
Bottom constructions
Welt-attaching plantsGoodyear weltedForming, lasting, welt attachment and sole stitching.Sole stitchingBlake stitchSole stitched through to the insole and upper; also called Little Way in our range.Bonded sole attachmentStuck-onLasting and moulding, bonded sole attachment and infrared curing.Automatic stitchingStitch-downThe turned-out upper edge stitched to the sole.Moccasin pre-formingHand-sewnPre-forming and upper shaping for the moccasin form.Sole stitchingSidewallStitched through the sole sidewall, then rolled and trimmed.
Scale
Capacity to grow into.
Experienced operators bring the judgement each material and construction requires, line after line.
Quality control and AQL6 millionPairs of annual capacity
20Production lines
3,000+People
6Facilities
Enquire
Tell us what
you need.
Share a few details and our team will be in touch.