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A brief explanation of 250 operational steps – a look behind the scenes

It takes over 250 work processes and more than 60 individual components to produce a comfortable and high-quality pair of safety shoes. Read on to find out more about how we produce our safety shoes and why we do so much by hand – take an exciting look behind the scenes.

The Stuco quality philosophy: Over 250 operational steps to produce a Stuco safety shoe.

Cutting

The production process of any shoe begins with the cutting of the leather and fabrics. State of-the-art cutting robots cut the required components from high-quality cowhide or buffalo leather, and fabric and foam components.

Stitching

Stitching shoes is a process that requires great skill and expertise: On the one hand, the materials are thicker than normal textiles and on the other hand, the shoe is a highly complex three dimensional structure. Stitching robots are out of their depth when it comes to giving the shoe its form. This is the process where the skill and precision of our experienced stitchers comes into the equation. Altogether, there are usually some 30 to 40 individual components that have to be stitched together, depending on the shoe model. Only after this process, can hooks, eyelets, and at best trim, then again be added to the shoe upper using machines. The final step of this process is the stitching of the insole to the shoe upper – the form of a shoe can now be seen.

Assembly

This process involves the assembly of the shoe; the outsole, steel toe cap and lining are now added to the semi-finished product. Depending on the shoe model, the outsole is either glued or stitched with a double seam. The sole and shoe are bonded together using a two component glue, heat and high pressure; however, they maintain their elasticity.

Quality Control

The shoe is checked and has to meet standardized quality criteria after every single step of the production process. At the end of the production process, the finished shoe is then cleaned and treated, and inspected once more. Only then is it carefully packed into the box and sent to the customer.