Machines give us consistency. People give us repeated inspection. Every ball passes through many pairs of hands between raw rubber and the carton, and each one is a chance to catch a defect.
All raw materials and rubber chemicals are sourced pharma grade and non-toxic. Each batch is lab tested by Bureau Veritas before it enters production.
Natural rubber is mixed with zinc oxide, stearic acid, sulphur, calcium compounds and other ingredients, then sheeted for moulding.
Hot steam and high pressure form the sheet into ball cups. Every cup sheet then passes through a conveyor metal detector.
Cup edges are ground for a rough bonding surface, adhesive is applied and two cups are joined into a hollow core.
Adhesive is applied to the back of the felt, which is then die-cut into the panels for each ball size.
Each core is covered with felt by hand. A team of about 25 people, each covering around 1,000 balls a day.
The white rubber layer is applied by hand in the gaps between felt panels, forming the familiar seam.
Balls are steamed in molds to complete forming. Any extra felt ridges are trimmed by hand.
For squeaky balls, the squeaker goes in through the engineered port. Then final inspection, metal detection and packing.
Our output is set by two stages: how many cups the presses form, and how many cores the felt team can cover by hand.
Factory visits and third-party audits are welcome by appointment. Audit reports and test certificates are shared with buyers on request.
