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Our
Sofa Manufacturing Process
Each of our sofas undergoes a
hand-crafted
process that results in the
highest quality product. We are happy to share the details of our
hard work to provide you with a deeper overview of the production
process.
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STEP ONE
Solid Wood Frame
Preparation:
Wood Cutting
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In this step the wood is precisely cut
to provide
the solid framing for each sofa.
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STEP
TWO
Solid Wood Frame
Preparation:
Wood Assembly
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The wooden cut-outs and heavy metal gauge wire are assembled to
construct the initial shape of each sofa's style. The belts system is
applied to support the dense foam. As you can see in the pictures below
durability is our number one priority.
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STEP THREE
High Density Foam
Preparation:
Foam Cutting and Bonding
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In this stage the specialized foam is being cut to cover the seating
area, with special fibric fillings (softer foam) covering the armrests,
seat and backrest to provide the most comfort and support for all the
body's delicate points.
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STEP
FOUR
Top-Grain Leather
Preparation:
Leather Cutting and Sewing
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Now the padded frames are ready to be outfitted with our top quality
genuine leather through out the foam seating area.
Leather is cut in multiple pieces to cover each section of a sofa
individually. This process provides perfect leather upholstering.
After the leather cutting part, the leather is ready to be sewed
together with special extra-thick threading to provide many years of
use.
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STEP
FIVE
Finishing Manufacturing
Process:
Leather Fitting
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Leather fitting process is a tedious process where every tiny inch of
leather piece is sewed, glued, blocked and nailed to the frame.
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Each leather piece is slightly stretched to provide an ultimate smooth
surface for a luxurious touch and feel.
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STEP SIX
Final Production Step:
Inspection Quality Control
and Heavy Packing
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Finally, a thorough inspection is performed by the supervising staff.
The inspection is done in a specially designed super-bright room, which
allows a better observation of the finished product.
Once inspection is completed, the new products are ready to be packed
in: foam, cardboard, shrink wrap and special sturdy rice bags.
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STEP
SEVEN
Loading and Shipping
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The final step is loading the containers with the goods, after which,
the containers will be loaded on carrier ship heading on a long journey
to our New Jersey warehouse.
During loading of the containers, each piece is put into the containers
by hand! This is done to avoid any possible damage.
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