A Look Inside Our Western Boot Factory

From the initial design concept to the final product, we are dedicated to producing boots that are stylish, durable, and comfortable for our customers. Our skilled craftsmen and women take pride in every pair of boots they create, using traditional techniques combined with modern technology to ensure the perfect fit and finish. So, come along with us and discover the secrets behind making our Western boots.

Reviewing results

Let's start in the design department. But before our designers start creating, they must analyze the sales data obtained. This data shows the most purchased sizes and the most requested models in stores, according to the region and country. Based on this, the team will establish how many shoe models should be released for the following collection, whether they should create new shoe lasts, new combinations, or experiment with new products.

Through fashion shows attended and trends seen in WGSN (a company dedicated to trend forecasting and consumer insight), they choose the trends that best fit our brand essence. Did you know of the existence of this company? With them, the creation of our color palettes and accents for the outgoing season separated them by region: Latin America, North America, and Europe.

Once the presentation is made about what is going to be developed, it is sent to other areas of the factory to see what supplies are in stock and what could serve for the collection to be set, such as hardware, trimmings, leather, soles, etc.

Inside the Creative Hub of Our Company

After the information from the other areas is gathered, the plan for the collection development is created. In this plan, the designers are tasked with creating one shoe per month, that is, to have 44 models of men's and women's shoes ready for retail in 7 months. In this line sheet, target prices are established based on sales information. Models are classified (boots, dress shoes, sneakers, among others), shoe lasts to be used or developed from scratch, and the type of construction and stitching. Based on the information from the supply area, the existing leather and materials are evaluated to make the most of them. This is where the material logistics take place, as once the models are designed, the materials that are not in stock must be requested. For this purpose, the materials list, leather projections, hardware, trimmings, and other line materials are created for each collection.

When a new last is created for the season, various material tests are carried out, fitting tests are conducted by our executives, size scales are developed, and possible combinations of models with the same sole are evaluated for the release of the line. The line is classified for Cuadra, Franco Cuadra, or another one of our brands. This is how we gradually build up a “soles buffet”, a variety of lasts to choose from for future creations.

Before designing the collection, it goes through various filters, such as the approval of sketches by one of the owners creating a sample in non-exotic leather to see if any modifications are necessary. The model is finished and approved when it has its own line sheet of materials, a nearly accurate sketch, and its own production instructions, resources to be used (machines), the construction skeleton, pre-finishing and decoration process (hand-shading by our artisans).

Before going into more significant production, a sample is made in exotic leather, which is the final material of the product. It is verified that the production costs match the target price, and if not, adjustments are made before launching the pilot batch. During this pilot phase, we can see the engineering team working on the next step.

Crafting Quality and Innovation in Every Step

The engineers receive information from the designers and verify that the process is well-developed to create cards for each model. At this stage, the engineers become familiar with the characteristics and properties of the leather and identify what improvements can be made. These cards are created to send the design system and the process for each product to the factories. The engineers ensure the cuts are correct, and the scales have the appropriate dimensions, and all necessary materials, hardware, and accessories are requested. Each model has its own card in the system, so the information is readily available when needed. This area also explores new ways to optimize labor and facilitate the creation of products for our workers. This includes using laser cutting, marking guidelines for stitching, cutting, and gluing, and ensuring proper finishing without interrupting other processes. Imagine having to unstitch something to finish the procedure to have an impeccable product. Engineers have it covered; all systems fit like clockwork.

Assembling

In the factory, there are many ways of working, whether it's with a hydraulic swing arm clicker press cutting machine for standard leather or hand cutters with molds experienced in exotic leather, in which they ensure that the cuts are mirrored and have almost the same appearance so that the final product has a similarity among them when assembled. 

Alongside this is the soles area where different soles like TPU injection machines, cutter machines for wood, leather, or mixed technique are made. In this part of the factory, the cuts of the insole sizes begin, whether for the interior or exterior of the boot, they are thinned to the desired thickness; excavations are made if a type of TPU like the one in the image with laser engraving is to be inserted, apart from the way the sole needs to be curved for the boots, the scraping so that the heel can adhere and the necessary nails and firm structures can be put in place. 

Going back to the leather, once the pieces are cut, a white outline and notch marks are made, which helps the workers know which part of the piece should be sewn, glued, trimmed, or thinned so as to avoid having thick folds or seams that may bother the user while walking with the shoe or be seen in the final shoe design.

Little by little, the boot takes shape, and things like the toe cap and counter are included in the toe lasting, which, although not visible in the final product, can be felt and are fundamental to the quality of a boot, ensuring that the toe is firm as well as the heel. They are passed through stabilizing ovens to adhere to these structures and start forming the boot mold, where the hot glue is cooled to maintain the desired shape. Likewise, they are put in hot and cold tubes so that the leather can form according to the design; this serves as activation and memory for the leather. To prevent the leather from being overstretched or deformed, these pieces have a specific interface so that they are only stretched as necessary.

The two processes of assembly of soles and leather pieces are now joined for the final finishing process, which requires a lot of technique to avoid a boot with folds or wrinkles when creating the final product. This step is not only glued but stitched for a truly durable finish that will not peel off apart. At this stage, we can already see the product without the shading of the paint, which is now done by hand, with airbrushing, polishing, and hardware cleaning. Passed through the eye of our quality control team, it is ready to be packed and taken to the requested stores.

In conclusion, creating a high-quality boot requires a team of skilled professionals and a commitment to excellence. From the initial design phase to the final finishing touches, every step is critical to ensuring that the end product meets the highest quality and durability standards. The combination of traditional craftsmanship and cutting-edge technology sets this factory apart and makes it a leader in the industry. The passion and dedication of the team are evident in every pair of boots they produce, as you can see on our social media. It's no wonder these boots have become a symbol of quality and style worldwide.

 

Thank you for your interest in our blog! We hope you have found the information herein to be helpful and informative. We welcome your feedback and would love to hear from you. If you have any questions or comments, please feel free to contact us.