Our 4.0 factory based in Alsace
In 2020, we inaugurated our new 4.0 factory in the heart of Val-de-Moder, just a few steps away from our logistics center inaugurated in 2016.
With its 2,600 square meters dedicated to injecting the soles of our safety shoes, this factory embodies our commitment to a more sustainable and responsible enterprise, without ever compromising on safety and quality.
In this perspective of local and environmental development, we have implemented energy recovery systems as well as low-energy LED lamps, contributing significantly to reducing our energy consumption.
Furthermore, we have redesigned the layout of our workstations to provide our employees with an ergonomic and pleasant working environment, which earned us the France Relance trophy.
Now that you know more about our factory, let's discover the jobs behind the injection of the soles of our safety shoes.
The steps of injecting a safety shoe sole
Logistics upstream of sole injection
Every week, our team of operators ensures the receipt of goods from our subcontractor through weekly deliveries by truck.
The uppers, essential components of our safety shoes, undergo initial quality control and are checked against the packing list before being carefully stored in anticipation of the next stage of the manufacturing process.
Preparation of the molds
Freshly out of quality control, the uppers join the stock where the upstream logistics team takes over. This marks the beginning of a new stage: preparing the molds for sole injection.
The cartons of uppers are transported to the injection machines, robotic carousels. It is there that the operators work to place them with precision, ready to receive the sole injection.
Next, the environment distributes the safety shoe uppers to the carousel stations that need them, ensuring a constant and optimized flow. Meanwhile, the molds are prepared for future changes, if necessary, before moving on to the sole injection stage.
Sole injection
Under the watchful eye of our experienced injectors, the upper is formed on the machine and the rest of the mold ensures the desired sole impression.
The carousel rotates in a circular motion while the injector remains stationary, and the polyurethane injection is carried out in the mold.
The polymer is injected at high pressure into the mold, first through the outsole and then connected to the upper by injecting the comfort sole. This process, called dual-density injection, guarantees a robust and durable shoe. Within minutes, the material spreads inside the mold, filling every detail of the sole.
It is thanks to this reaction that the sole binds to the upper, before solidifying as it cools. Once the chemical reaction is complete, the mold opens to reveal a complete safety shoe, with all its assembled elements.
Finishing and control of sole injection
Once the soles are formed, it is the skilled hands of the trimmers that take over. Using a trimming machine, they remove any PU burrs that may escape from the mold and joint plans.
Nothing is left to chance. Our inspectors inspect each shoe meticulously, ensuring their compliance and quality, including mandatory components on certain models, such as protective toe caps.
Once validated, the safety shoes are carefully stored by model and size on a dynamic rack. This system ensures quick and efficient access to each pair.
Insertion of the comfort sole
This is the ultimate step before safety shoes are packaged and shipped.
The installer works to insert the comfort sole, also known as the insole, into the safety shoe.
Usually made of comfort foam coated with fabric, this insole is designed to offer you optimal well-being throughout the day, while promoting foot breathability.
Depending on the models, the installer may also finalize the lacing or specific lacing system installation.
Final step: packaging and shipping
And here we are at the ultimate phase: packaging and shipping the safety shoes.
Our packers take over to meticulously pack each pair of safety shoes, placing them in American boxes on pallets, ready to be shipped by our logistics service.
It is our logistics teams who then take over to prepare the orders and distribute the pairs of safety shoes to our partner distributors, before they finally end up on your feet!
In addition to the mentioned professions above, other essential jobs contribute to the success of injecting our soles: maintenance, mold cleaning, research and development, these invisible teams work upstream and downstream of the process to ensure the impeccable quality of our products.
The benefits of injecting soles for safety shoes
At LEMAITRE, innovation is at the heart of our DNA.
From our inception, we made the bold choice to adopt the injection technique for manufacturing the soles of our safety shoes. Why? Because this method offers a multitude of unparalleled advantages for your safety and comfort.
No more detaching soles! Injection ensures perfect adhesion between the upper and the sole, even in demanding work environments subjected to difficult conditions.
Flawless waterproofing! Thanks to injection, the sole becomes a real barrier. Its optimal waterproofness protects your feet from moisture and chemical substances, ensuring increased safety in work environments where protection against liquids is crucial.
Unparalleled comfort! Injection also offers unmatched comfort. The injected sole effectively absorbs shocks and vibrations, thus reducing fatigue and the risk of injuries.
Exceptional wear resistance! Made from quality materials, the soles injected in our factory resist abrasion and tearing, even after intensive use.
By choosing LEMAITRE safety shoes, you opt for optimal protection and unparalleled comfort.
Conclusion
Sole injection represents much more than a simple choice for us. It is a strategic decision rooted in our deep commitment to the safety and well-being of workers.
And it is thanks to the dedication and expertise of our teams that we are proud to contribute to the protection of workers, by providing them with reliable and high-performing safety shoes, allowing them to work with confidence day after day.