Manufacturing Process - ZA Bold Wear

Manufacturing Process:

The ZA Bold Wear team’s dedication lies in prioritizing the most essential aspect of a thriving business treating our customers as part of our family We ensure that investing in one of our beautiful leather goods isn’t just purchasing a high-quality item that lasts a lifetime; it’s embracing the belief that our customers, define our uniqueness not our products,. We utilize the finest materials to craft essential handmade leather goods at an accessible price point, creating timeless collections that only grow more exquisite with age. Each piece is lovingly handcrafted using the best methods, leathers, and materials available, ensuring that all designs are 100% leather and develop a rich, distinctive patina over time.

Step1: Selection of Leather

Choosing the ideal leather for our products proved to be an extensive learning process. Initially, our search focused on finding leather with the desired appearance and feel. However, as we explored various local leather shops, we discovered that identifying the suitable material was more challenging than anticipated. Only a very small portion of the available leather met our standards for use in production. Each jacket is made from scratch in our warehouse by our skilled team of experts. We primarily utilize premium lambskin hides in the production of our leather jackets. Lambskin leather is widely prized in the fashion industry because of its softness, resilience, and natural grain pattern. Its superb quality and adaptability make it a popular choice among designers and consumers searching for high-end leather items. Furthermore, we utilize cowhide for the production of rugs and other items in our collection.

Step2: Tanning

Today, almost all (around 95%) leather products in the fashion sector are made from chrome-tanned leather. They are made in just a couple of days, making them much more affordable than leather that has been vegetable-tanned. Chromium salts are used in this technique to make it possible. Our specialists utilize their expertise to speed up tanning processes. The skin comes out from the process as light blue and pale so, they need to be dyed and painted to receive the final look. Leathers that undergo vegetable tanning are crafted in large drums using natural ingredients. This traditional method spans up to four weeks, resulting in a higher cost compared to other methods. Presently, only a few brands opt for this technique. The natural look of this leather closely resembles the human skin tone, emerging from the drums with this inherent color. Vegetable-tanned leathers usually have a very subtle natural smell. They are more resistant and more robust than chrome-tanned products.

Step3: Washing and Drying

Following tanning, the skins are carefully wrung out and given another wash. Subsequently, the skins undergo a band knife cut to achieve a consistent thickness, after which they are transferred to drying tunnels via conveyor belts. To combat the stiffness that drying produces, the hides are sprayed with water and soap and allowed to hang for some time. The hides are buffed using rotating steel cylinders wrapped with abrasive paper once they have been completely dried out. Although this stage does require a greater amount of effort and conditioning work, it is necessary to achieve an incredibly smooth texture which will facilitate shaping the leather into our higher-quality leather jackets.

Step4: Design

1- Leather Inspection:

It is impossible to omit the inspection phase for leather. Our leather jacket can only be made from premium leather. We conduct an extremely thorough inspection to ensure that, the skin of the animal resembles that of our people. They may be flawed in one way or another, with wrinkles, scars, and other issues. We are inspecting to make sure the leather we use is scar-free. A leather jacket typically uses three pieces of leather, so we examine it to make sure the grains, pore sizes, and color of the pieces are all almost the same.

2- Cutting:

Our main goal is to create a jacket that will endure for many years, retaining its stitching intact. The requisite leather pieces are carefully assembled by our warehouse professionals for the jacket’s exterior as well as interior designs. For the jacket’s noticeable areas, we would cut a piece of high-quality leather from the middle (the best section). We would utilize leather from the limbs and belly for areas that aren’t too noticeable, like the underarms. A dedicated individual inspects every piece of leather after it has been cut to make sure there are no flaws in the finished item.

3- Patterns:

Design excellence remains at the forefront of our product ethos, particularly in crafting our jackets. Our commitment to delivering exceptional results drives us to employ an array of design elements, harnessing the capabilities of advanced computerized tools. Furthermore, we implement specialized techniques customized to align seamlessly with the unique style inclinations of our clientele. This dedicated approach ensures that each garment meets our high standards and resonates perfectly with our customers’ preferences.

4- Lining:

Following the cutting, the leather passes through the lining. This technique helps to strengthen the leather’s elasticity and prevent the jacket’s pattern from distorting after years of use. We only use the softest and most skin-friendly viscose lining since it improves the jacket’s overall comfort level. This makes the clothing more comfortable to wear by providing a natural and comfortable sensation against the body in addition to greater warmth.

5- Marking:

Ensuring that the final jacket sizes follow standard measurements is significantly dependent on marking. Manufacturers guarantee exact alignment with specified sizes and proportions. The jackets will ultimately meet according to predetermined standards due to the rigorous marking process, which also preserves quality and consistency across the production line.

6- Sewing:

After Marking, each cut-out piece would be sent to be sewn accordingly for sleeves, front, and back areas.

7- Final Pressing:

This is almost the last step that our jacket undergoes. The function of final pressing is for our finished garments to reach consumers’ hands with high flatness and shape. Consumers are not suggested to iron their jackets back at home, only professional ironing masters and dry cleaners can do this. After we iron the jackets and send them to our customers, the only thing they need to do is to hang them for ‘I to 2 days and the jacket would be flat without ironing.

Step5: Quality Checks

The most important phase in the production of leather is quality control. It guarantees that the leather used satisfies the requirements for performance, durability, and quality. For use in any application, it is crucial to make sure the leather is defect-free, has the right specifications, and complies with safety regulations. We use strict quality control procedures to ensure that, over time, your product will fulfill and even surpass your expectations. Before shipping, our committed inspection team carefully examines the following issues.

Inspect incoming leather: Begin quality control by checking color, texture, shrinkage, and defects in incoming materials.
Set quality standards: Establish clear standards for physical properties, chemistry, and manufacturing processes.
Use advanced equipment: Employ tools like digital gauges, camber meters, and thermometers for precise testing.
Employ sampling techniques: Use visual, physical, chemical, and analytical methods to verify leather quality.
Monitor production: Supervise cutting, stitching, dyeing, and finishing stages closely.
Ensuring impeccable stitching quality.
Identifying and correcting any flaws or defects.
Guaranteeing meticulous finishing across all elements—cuffs, collar, buttons, zippers, pockets, and beyond.
Set up quality assurance: Implement a system for regular process and product inspections.
Document controls: Maintain records of materials, tests conducted, and their results.
Embrace customer feedback: Utilize customer input to improve and meet expectations. Our dedication to quality encompasses every facet of your jacket.

Step6: Packaging

After affirming the jacket’s quality and adherence to specifications, our team undertakes a comprehensive final examination before transferring it to the packaging section. This exhaustive assessment guarantees the jacket’s pristine condition, ensuring it’s fully prepared for its intended use. To bolster stability during transportation and safeguard against potential freight-related harm, we take the additional measure of encasing all our items in custom-designed bags tailored for leather jackets. Our foremost concerns are your contentment and ensuring the secure delivery of your jacket.

Step7: Delivery & Shipping

Our shipping hinges on established courier services renowned for their rapid and reliable delivery, partnering with reputable companies like Fed Ex and DHL. Once your package is dispatched, an assigned tracking code will be provided, enabling you to seamlessly track your order’s progress as it makes its way to you

Order processing and shipping occur within a timeframe of 7 to 10 business days from the date the order is placed.

Above all, we care about you. Our network of sales representatives, agents, and upholstery experts is committed and well-trained. They share our commitment to providing exceptional customer service, creating innovative products, and identifying the ideal leather option to fit your desires, application, and financial constraints.

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