(134).Start a Plastic Footwear Making Plant
The plant outlined in this proposal is just one of several dealing with the production of shoes. However, this plant is unique, in that many types of materials may be used to produce a wide variety of shoes including: PVC shoes, sandals, and slippers, genuine leather boots, high-heeled shoes for women, dress shoes for men, as well as a wide variety of casual shoes for men and women. The benefits of establishing a plant with the capability of producing such a wide variety of sizes and styles are obvious, particularly from a marketing point of view. An equally important benefit of operating such a plant is the fact that these shoes can be made from so many different types of material including leather, synthetic leather, canvas, and nylon, as well as PVC, PU, EVA, and rubber. The owner of such a plant can be sure he wills he able to keep up with the demand generated around the world for a wide variety of shoes. Of course the demand for shoes will never decline. Virtually, everyone in the world wears shoes everyday of the year and as the world’s population and its standard of living increase, the quantity of shoes sold in a given period of time will increase proportionately. All of this, in conjunction with the fact that shoes inevitably wears out means that the demand for shoes will continue to raise. This, of course, is no secret to the manufacturers of shoes in the Republic of China, which have, for more than twenty years, been involved in improving the methods and machinery used in producing shoes of all types. The endeavors of these companies have made the Republic of China the number one exporter of shoes in the world. It is, therefore, only logical that anyone wishing to make an investment in any country where the people desire to purchase comfortable, attractive, durable, and inexpensive shoes, would want to take advantage of the years of research done by the shoe makers in Taiwan and purchase the shoe making plant outlined in this proposal.
General Process Information
Process Description: Since a single plant can produce so many types of shoes, it is not possible to go into a full process description of every shoe. However, the process of making ladies shoes described below outlines the basic steps involved in fabricating most kinds of shoes.
- Material Preparation
The cutting die being used determines the size and shape of each segment. If leather is being used, it is first split into the desired thickness.
- Folding and Binding -before being sewn together, the edges of each segment are automatically folded and bound.
- Stitching -The bound segments of material are then sewn together by a sewing machine to form the upper of shoe, as illustrated in figure number 2.
- Thermoplastic toe boxes, designed to provide support to the toe of the shoe, are made and inserted by a toe-puffing machine. At this point, the uppers are forwarded to the assembly line for further processing.
- Insole -The material used to make an insole is cut into the desired shape and size by the same machinery used in cutting the uppers.
- These segments of material are glued to the shank and shank-board. After gluing, the mid sole is molded to fit the sole of the shoe, as illustrated in figure 3.
- Sole and Heel -The soles and heels of shoes can be made from PVC or a wide variety of other materials including leather, rubber, cork, and synthetic leather. Heels and soles made from materials other than PVC are assembled from preformed materials as illustrated in figure 4. The process of making PVC soles and heels described below is also the process, in its entirety, of making the PVC sandals, slippers, and shoes mentioned in the introduction.
- The appropriate quantities of coloring and forming agents are added to PVC and mixed to a consistent texture. (It should be noted that premixed materials are readily available on the open market.)
- The PVC mixture is then fed into the holding tank of the direct injection-molding machine.
- The appropriate molds are attached to the machine.
- The machine then automatically heats, mixes, and injects the PVC mixture into the mold cavities.
- After solidification has taken place, the molds are opened and the shoes or soles are removed.
- Both the heel and outsole re purchased from the outside source. The heel is cemented, coated with heel lift, and then sealed with top lift, then sealed with top lift. Finally the heels are cemented with the outsole as in figure 5.
- The shoes are visually examined for flaws, packed, and then stored or shipped.
- The PVC soles are forwarded to the assembly area.
- Production Lines:
- Lasting: The insole in nailed to the last and the back part of the upper is molded into shape by machine designed for that purpose. The completed upper is put into the last and lasted by the lasting machine as in figure 6 and 7.
- Forming: The sole is cemented to the upper by using high strength glue and heat-set as in figure 8. The sole is pressed to ensure the seal with sole attaching machine.
- Arrangement & Packing: The shoe is cooled and removed from the last as in figure 9. Then, the nails are imbedded in the heel with machine. Any thread or other waste material is removed by a hot air blower. Foot patch is inserted into the shoe. The metal detector is used to check for needles which protrude from the shoe during the manufacturing process. Finally the shoe is cleaned and visually inspected for flaws or defects and packed into boxes.
- Finishing, Inspection and Packing
- Any thread or other waste material is removed by a hot air blower. Shoelaces and insoles are inserted into the shoes. A metal detector is used to check for needles, which may have been imbedded in the shoe during the manufacturing process. Finally the shoe is cleaned and the shoe is cleaned and visually inspected for flaws or defects and packed in to boxes.
Production capacity: The production capacity of a plant will vary depending on the number of machines used, the allocation of manpower the overall production efficiency and the type of shoe being produced. For example, a plant equipped with the machinery and equipment described in section 3.4, utilizing the number of workers described in section 3.3, should be able to produce 2000 pairs of ladies shoes per eight hours. However, inefficient operation of the plant could drop that figure to as low as 1200 pairs for the same period of time.
Raw Materials: The materials needed to make ladies shoes are listed below. Few other materials, if any, would be needed to make other types of shoes.
- Box toe: Thermoplastic
- Upper: Wet PU sheet, Dry PU Sheet, Canvas, Leather, Nylon Cloth
- Lining: Dry PU Sheet, Split Leather, Foam, Tricot
- Foot Patch: Sponge, Foam
- Counter Pocket: Non-Woven Cloth, suede
- Heel: ABS, #475 ABS, Cork
- Heel Lift: Dry PU Sheet, Wet PU Sheet, Cork
- Top Lift: Injection-PU, Nylon, PVC, Cutting-PVC, Rubber
- Outsole: PVC, PU, EVA, Rubber
- Insole: Texon, Supertex
- Shank: Low Heel-Iron (1.2mm or 1.0mm)
- High Heel-Steel (1.2mm or 1.0mm)
- Shank board: Red, Blue or Black Hardboard (2mm or 1.5mm)
- PE Bag
Machinery and Equipment
Machines for Insole Molding division:
Insole molding conveyor (18m long)
(include 1-9.6KW heating case,
Shank board skiving machine,
Shank riveting machine
Mid sole molding machine, and
Insole shaving machine)
Machines for sole injection molding division:
Mixing & drying machine
Injection molding machine
Machines for Cutting Division:
Hydraulic cutting machine
Machines for Stitching Division:
Leather skiving machine
Edge folder for vamps & leathers
Edge binding machine
Flat bed single needle sewing machine
High post double needle sewing machine
High post single needle sewing machine
Trimming machine for inner lining & sole
Thermoplastic toe puff applying machine
Machines for Production Line Division:
Lasting conveyor (18m long)
(Including 19.6KW heating case and vulcanizing machine)
Forming conveyor 20m long
Including 1-2.4KW, 1-6.8KW, 1-9.6KW heating case and rapid cold forming machine
Arrangement & packing conveyor (12m long)
Air nail tool
Back part molding machine
Front lasting machine
Rear rimming machine
Sole grinder machine
Sole attaching machine
Last slipping machine
Heal nailing machine
- Shoe Lasts -Approximately 1,200 pairs of aluminum or plastic lasts are needed for each production line.
- Tooling Equipment -Some hand tools will need to be purchased such as: tensile strength tester, hammers, pliers, are measuring needles, cutting dies, hold punches, and scissors.
- Spare Parts -Any spare parts needed during the first two years of operation will be supplied. This will account for approximately 10% of the total investment.
Utilities: Electricity 150KW
Plant Site Planning: A shoe making plant located in any region where adequate supplies of the raw materials needed are easily accessible, should have no problem making money, providing the area in question is developed enough to provide electrical power, adequate ways and means of transportation, and a capable work force.
List of Suppliers:
King Steel Machinery Co., Ltd.
No. 22.7th Rd., Industrial Park. Taichung, Taiwan.