Development & Production
An overview of the manufacturing process of PT. Gradial Perdana Perkasa’s export quality shoes.
Depending on request, buyers often provide shoe designs or refer to our in-house designs inspired by trade magazines and catalogues. Shoe pattern is drawn on the shoe last and transferred to a paper pattern. The pattern is then hand-cut or cut using a machine operating under Cad Cam or other shoe design softwares.
The cutting process consists of two types: leather-cutting and sole-cutting. In leather-cutting, thin sheets are manually cut and stitched based on the chosen design and pattern. The making of a sole involves cutting thick sheets of rubber or any other sole material using a sole-cutting machine, followed by the application of lining to soften the leather and strengthen the sole.
Shoe-stitching requires great skill and precision due to the thicker materials and the complex shoe structure. Depending on the shoe design, there are some 30 to 40 components that need to be stitched together. Hooks, eyelets and trims are added to the shoe upper using machines. In the last step of the stitching process, the insoles are sewn onto the shoe upper.
“The human foot is a masterpiece of engineering and a work of art.” ~Leonardo da Vinci
A plastic mould in the shape of a foot is used in the assembling process. The upper part of the shoe and the insole are glued together. The mould is then removed. In the pressing process the shoe containing the mould is placed in a machine which presses the upper part of the shoe to the sole to ensure proper adhesion.
After pressing the shoes are allowed to dry for a specific amount of time. The moulds are then removed and the finishing process begins. The sole edges and heels are trimmed, buffed, stained (for waterproofing), polished and waxed to give a smooth finish. A “finished shoe” is now made.
The finished shoes are stamped in the name of the customer or brand using ink and foil paper. They are then cleaned, polished and sprayed according to the materials used for the uppers. In the next step shoe laces and tags, such as shoe care instructions, are attached.
After the final inspection to meet quality standards, the shoes are carefully packed into pre-labelled and bar-coded boxes according to the sizes and dispatched to the customers.