Craftmanship

An occasion demanding craftsmanship 

We could bombard you an amazing number of facts about making footwear, but we will keep it short and sweet and tell you how our ZOO Adventure boots are made with care. The love for the product is also very important in the factory. These boots are made with passion in Portugal because they also value ZOO Adventure products. 

After designing the sole and the shoe last, the model drawings follow and then we choose the materials. We won’t bore you by going through the preliminary stages of creating a collection; even though that is an art in itself to be considered at some point. If you are interested in reading about how the ZOO Adventure collection started, you can take a look at “Since 1977” which will explain how it all began. Now, we are going to move directly on to the place to be, the factory with the golden touch.

 
 

Making the patterns

The patterns are made in the factory, not like at home on the floor with pattern paper and pin cushion, but at large drawing tables. In the preliminary stages we make the knives, correctly position the sewing holes and divide the pattern sections among the skins before actually cutting the pattern with large and heavy equipment. This applies to the upper materials, the lining and also the interfacing. The edges of the leather of the cut patterns can be skived as desired.

Sewing 

The individual pieces of leather are sorted and go to the sewing department where they are sewn together by machine and by hand. The upper leather is sewn to the lining and then all the remaining pieces together to create a complete upper section. A special thread is used to stitch ZOO Adventure, Italian waterproof thread.  

Preparing lasting

Then we need to trim the edges. It’s gradually starting to look like something and the still rather shapeless upper section is almost complete. The shoe last comes into action and is dressed with an assembly sole under the foot. The sewn pieces of leather are pulled onto the shoe last, with the ends of the skin reaching the assembly sole. 

Lasting

The shoe last is embraced by a machine that extends two cushion-like arms holding the boot. After a firm embrace, the shoe last comes out of the machine and a true transformation has taken place, there is shape, a boot is born. 

Preparing the upper section

It’s not quite a finished boot yet, the upper section is still an ugly duckling that needs to grow into a beautiful swan. The upper section containing the shoe last is gently skived so it can be joined to the sole later on. But we are not quite there yet. The upper section under the foot of the shoe last on the assembly sole gets a dollop of special glue that is spread out by hand and with a bit of flair. 

Preparing the lower section

The upper section is warmed in an oven while waiting for the arrival of the outer sole. The soles are also delicately treated, the innermost part is carefully skived by a machine, cleaned and greased with an adhesive and heated in the oven to activate the glue. All ready to receive the upper section.  

Assembly

A diligent worker fixes the shoe last to a pin, pushes on the sole with precision making sure it’s in the right position. The boot is released from the pin and the parts are taken to a machine where the sections will be joined. This machine applies pressure to the upper and lower sections, positioned comfortably between the cushions, joining them together.  

Finishing

Connected as one, covered in fabric dust and smudged with dirt, the glue and any other imperfections are cleared from the boot. The removable insoles are put in the boots and they are ready to be checked to see if they are eligible to wear the ZOO Adventure label. 

Final inspection

After meticulous checks to ensure the intensive process has provided the desired result, the boots can be packaged. The boxes are prepared for transport. 

The boots are thus largely made by hand and are therefore unique. Due to its nature, the ZOO Adventure production demands particular care and expertise. A beautiful product for a beautiful personality.