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Factory Visits #1

Saddles - Made in Spain

In our "Factory Visits" series, we visit our manufacturers and suppliers to provide an exclusive insight into their production processes and selection criteria. In this article, we share our experiences of producing our saddles at Essax in Alicante, Spain.

Two years ago, we began searching for a suitable partner to develop a new line of saddles. Our goal was to manufacture the products in Europe using sustainable materials and to work with a company that shares the Procraft team's passion for cycling. We found exactly the right partner in Essax and have been working together ever since! Essax started out in the late 1980s producing ergonomic foam products made from recycled leather, synthetic textiles, and microfibres, and has since become a well-established company. In 2011, they began manufacturing bicycle saddles and have since focused entirely on their design, development and production. We were impressed by the company's long history of producing bicycle accessories, spanning over 40 years.

The manufacturing process

Essax was chosen because it combines modern technology with innovative expertise. It has a database of over 2,000 saddle impressions recorded by a team of biomechanics experts. The use of 3D printing also enables the rapid production of samples, significantly reducing development time. Essax relies on precise machinery to ensure the consistently high quality of its saddles.

The manufacturing process begins with the shaping of the lining and padding after product research and planning have been completed. The ergonomics of each saddle are based on detailed studies that inform the development of the individual padding layers. Once the individual parts have been manufactured, the saddles are produced using modern machinery. Highly qualified specialists then take care of the handcrafted padding and quality control processes that set our saddles apart.

The next step is to manufacture the prototypes. First, the raw materials and molds are selected and designed. Then, the prototypes are created and subjected to external testing and inspection. Once all tests have been successfully completed, the final design and series production can begin. This production process combines state-of-the-art technology with skilled craftsmanship. Highly qualified employees carry out this process, and it cannot currently be fully replaced by machines.

The production team creates the graphic design, which is then plotted onto the microfiber and cut to size. The cut pieces are fed into a vacuum system where the foam padding is injected.

The microfiber is then cut to size and bonded to the padding using organic adhesives to ensure long-lasting adhesion. Finally, the rails are inserted into the prepared holes and secured.