Production & Sustainability

Would you like to know how our shoes are made? Then you've come to the right place.

Step 1 - The Cutting

The production of a shoe begins with the cutting.

Cutting mainly refers to the components for the upper part of the shoe, including the laces and strips, and in the shoe factory there are cutting stations for manual cutting, mechanical cutting and laser cutting.

Laser cutting is extremely precise and is used to cut the most delicate materials, while the other components of a shoe (bottoms, soles, heels and packaging material) are already in the factory when cutting begins. This is very important because after cutting and sewing, all these components are assembled into kits so that they stay together during assembly.

Step 2 - Sewing and Stitching

Sewing and stitching is the heart of a shoe factory and the most complicated and labor-intensive part of shoe manufacturing.

This is where the upper part of the shoe is sewn together.There are many sewing machines in the factory, operated by talented seamstresses. The machines are also different because each shoe model can have different types of stitches.

At the end of the sewing and stitching process, it's time for the first quality check!

Step 3 - The Assembly

It's time to put the whole shoe together!

An essential component is the shoe last, around which the whole shoe is mounted.

This is a foot-like shape made of plastic, carved wood or cast aluminum.

Each shoe model has its own shoe last in all different shoe sizes. The shoe last is crucial because it determines the size, silhouette and outline of the shoe.

Different shoe models can pass through the assembly line at the same time. At the end of the assembly process, each shoe is cleaned and subjected to a further quality check before being packed into the shoe box.

Later, all shoe boxes are properly conditioned in transport boxes. Because soon a long journey awaits - to Germany. This is where we store all our shoes and wait for you to fall in love with them.

Are you wondering about waste management, environmental protection or working conditions?

Our manufacturers have a waste management system and work according to the so-called "zero environmental impact policy".

Thanks to these measures, 95% of all production waste is recycled. The remaining small percentage that cannot be recycled is professionally disposed.

A wonderful example of recycling is the use of the remains of some materials as padding between the insole and the midsole and then again between the midsole and the outsole. This cushions the shoe so wonderfully and makes it so comfortable that you feel like you're stepping on clouds.

ESG practices in the Brazilian footwear industry

Some key points on ESG practices in the Brazilian footwear industry in 2022

Source: "Relatório Setorial da Indústria de Calçados 2022", by Abicalçados (in Portuguese)

Abicalçados is the Brazilian footwear industry association.

87%

of companies have complete or partial production facilities for environmentally friendly waste disposal.

73%

of companies carry out the control of restricted substances.

60%

of companies state that they carry out eco-design initiatives for their products.

48%

of companies consume electricity that comes 100% from renewable sources, e.g. from the contract free market environment or from in-house generation (photovoltaics, wind power, etc.).

61%

of production is linked to companies that publish sustainability reports in accordance with international standards.

56%

of production is associated with companies that keep emission inventories.

Know the special features of Brazil

Brazil has the lowest CO2 emissions as a percentage of GDP (kg/USD GDP) compared to the world's largest shoe-producing countries.

CO2 emissions per USD of GDP are six times lower than emissions in Vietnam, four times lower than emissions in China and twice lower than emissions in Indonesia (World Bank).

CO2 emissions

Compared to the world's largest shoe-producing countries, Brazil has the largest share of renewable energy in its energy consumption.

47.1 % of electricity consumption in Brazil comes from renewable sources (wind, hydropower, solar energy, etc.). In China, the use of renewable energies is only 13.1 % (World Bank, 2018).

Consumption of energy from renewable sources
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