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OUR PROCESSES

Production

From Italian design to international production facilities: an integrated process that guarantees quality, efficiency and rapid distribution.

Our global approach

The main production plant is in Tunisia: with 100,000 square metres and 4,200 employees, it handles the medium-high-end ranges. The final stages are entrusted to a plant in France. Selected Asian manufacturers take care of the basic ranges. For technical apparel, R&D and industrialisation are managed by the Group, while production is outsourced to Asia.

From idea to prototype

The design process is managed in Italy by a team that develops around 500 new prototypes every year. It starts with a market analysis:

Examination of adjacent markets (such as sports and
outdoor activities).

Dedicated sessions with technical material suppliers.

Marketing Intelligence for a better understanding of the market, competitors and end-user needs.

Every year, U-Power offers around 1,000 new styles, renewing 20% of the product range. The styles are outsourced, tested in Italy and then sent to the production facilities in Tunisia or France. The entire preliminary phase takes around 3 months, with the ramp-up starting with the upper.

From prototype to production

The steps and timeframe are as follows:

Industrialisation of the upper (approx. 4/6 weeks)

Upper production (approx. 4 weeks)

Injection and finishing (approx. 2 weeks)

Efficiency and shared technology

At production sites in Tunisia and France, the Group develops and shares transversal technological solutions. A state-of-the-art structure guarantees high quality and optimised processes, supported by a local team and European managers.

Two plants, one standard

The Tunisian plant carries out87% of production, while the French plant concentrates on the final stages and covers about 6%. This synergy ensures high volumes and consistent quality standards across the entire range.

Internal ranges and processes

The Tunisian factory is divided into two areas: uppers and semi-finished products. Processing is carried out by joining lines and injection islands, with the possibility of increasing production when necessary. Each shoe passes through strict quality controls before reaching the market.

Control and continuous improvement

The production process includes waste management, maintenance and upgrading of machinery. Constant monitoring and testing ensure compliance with European standards and exceeding PPE 89/686/EEC.

Safety Standards

The Group's priority is to comply with the main safety and sole requirements.

More specifically:

Resistance to perforation

The impact and crushing of the tips

Dissipative capacity

The level of adherence

Resistance to repeated bending

Abrasion resistance

Tear resistance

The energy absorption capacity of the heel

Slip resistance