Bosco produces huge volumes on a daily basis. In addition to meeting all domestic requirements, the company is all set to increase its presence in the global markets.
Various footwear categories:-
Bosco has ventured into home, casual, sports and school wear. Currently, it has 4 footwear categories, namely, Sandals, Jogger, Leather, Joggers, and Schoolmate. P U, TPR, PHYLON, PVC, EVA, RUBBER It is one of the few companies that maintain consistent production activity in such a varied range of footwear.
Productions & Operation:-
The company has one of the strongest infrastructure in rubber footwear in India, and the best in the state of Rajasthan .Company is using the best of the technology of India and Abroad. Several imported machinery is used to maximized the productivity tools to optimize the value addition. The Quality control system ,motivated and dedicated team has made “Bosco” a strong brand. Research & development in new designs, chemicals, machinery, and many innovations is part of the daily routine .Our Lab is one amongst the best in India.
With the commitment to quality product, efficient value addition, penchant for customer service, satisfaction & relation, passion for innovation, company has grown a leader in Rubber footwear.
The manufacturing process of these eva injection moulded slippers is completed in four steps:
- Preparation of EVA Compound
- Injection for granules
- Injection of Straps and uppers
- Fitting & Packing
The manufacturing process of EVA injection moulded slippers can be summarized as under :-
Preparation of EVA Compound:- EVA compound is prepared by mixing EVA 1802 grade with other ingredients like colours, curing agents, blowing agent in kneader. This compound from Kneader is then passed through extruder, and finally through granulator to get EVA compound in the form of granules. These granules are then passed through water chamber for cooling and removing dust and are passed through numbers of cyclones for drying.
Injection of granules:- The granules are injected into sole mould placed on the presses of fully automatic computerized EVA injection machine. After curing of sole, presses open up automatically and an expanded sole comes out from Injection machine. The time, temperature and volume is maintained by computer, as per requirements.
Injection of straps and uppers:- PVC compound granules are injected to the straps mould through horizontal PVC injection machine.
Fitting & Packing:- Straps obtained from horizontal machine are inserted Into EVA sole. After quality checking, slippers are packed in C. B. boxes and finally to cartoon.
PU SOLE FOOTWEAR
The PU Sole footwear manufacturing process consist of three steps:
- Manufacturing of Synthetic Leather uppers and straps.
- Pouring of PU Liquid into moulds of shoes by pouring machine.
- Finishing & packing.
Manufacture of Uppers :-
To manufacture uppers from synthetic leather sheet, the Upper sheet is pasted with PU liner cloth by the lamination machine. Required uppers are then cut from the pasted sheet by putting on platform of upper cutting hydraulic machine and then placing knife on the sheet. The cut uppers then send for stitching by industrial sewing machines. After stitching, eyelets are inserted into the uppers by eyeleting machine and insoles (sox) are stitched by string lasting machine.
Pouring of PU liquid into moulds :-
In this process , first of all ready uppers are lasted. On the last of Shoes mould manually and then moulds are closed. These closed moulds are then kept on the 62 stations conveyer, which moves in anticlock wise direction. In this way the moulds keep moving along with conveyer. The conveyer stops for a few minutes under the arms of pouring machines where the PU Liquid (mixture of Poly isocyanate and polylol) is poured into hot mould by the nozzle fitted into the tubes carrying PU Liquid which comes through pump from the containers of Poly isocyanate and polylol.
The whole arrangement is fixed on the stand of the machine (arms). Before pouring the liquid into mould, moulds are cleaned by MCL Liquid and then mould-realizing agent is applied inside the mould, the moulds are heated by passing though the hot chamber, which is fitted, on conveyers. The setting of PU liquid in hot moulds starts gradually and after setting of PU, moulds are opened manually. Shoes are then removed from the mould and another upper is lasted on the last of mould for PU casting. The computer of the machine controls the volume of PU liquid, pouring time, time period and mould temperature.
Finishing & packing:-
After casting PU sole, shoes are shifted for checking, & trimming and then printed sponge insole is inserted into the shoes. The finished shoes are packed into Corrugated Boxes and finally into cartoon.
The process flowchart of manufacturing PU Footwear can be depicted as under.