Artesenal and 100% Made in Spain. Here is the manufacturing process of the StarVie rackets
The process is artesenal and 100% Spanish. The chronology of the manufacturing process is divided into 9 principle stages and are carried out in the StarVie factory in Azuqueca de Henares in Guadalajara. There a team of 22 people, including administration and craftsmen, work everyday to create the StarVie rackets!
The StarVie factory was founded in 2013 with the clear goal of having the manufacturing process in Spain, and thereby being able to closely monitor the manufacturing process from start to finish.
The factory is 2,000m2 in size with two padel courts that are used to test the new models.
Manufacturing process of a StarVie Racket
The chronology of the process.
Design. In collaboration with the factory in Azuqueca de Henares, this process is developed in the central office of StarVie, located in the centre of Madrid. At this point the design aspects of new moulds are developed as well as the aesthetics of the racket.
An important aspect is the time dedicated to the research, design and development. We are continually looking for new materials and shapes for moulds, in order to improve every aspect of every racket.
Casting. This is the first of the actual manufacturing processes. The materials, which are received in reels or planks are cut into the shape of the mould for that racket. EVA rubber and the materials carbon fibre, aramid (kevlar), basalt and fibre glass are used according to the type of model being cast, as each give different characteristics to the racket.
In order to comply with the requirements and quality policies of the company, all the materials used are sourced from premium providers and all meet the technical specifications required. The materials are also used in different sectors such as the aviation and automotive industries.
Moulding. In this phase, all the materials previously cut are then passed to a craftsman who impregnates them with a very important component, epoxy resin. Once this is completed they are put into the aluminium mould and after some time ‘cooking under controlled temperatures’ the racket is ready to move onto the next stage!
This process is one of the most important as here the playability and quality of the racket is determined. Randomly for quality control, a racket will be taken and cut to check the quality of the moulding.
Deburring. In this phase the cosmetic process starts. Deburring is the removal of excess material from the mould and after washing one by one, by hand with soap and a scouring sponge, the racket is ready for the next stage.
Manipulation. In this phase small defects are repaired and blemishes removed that may have occured in the moulding stage.
Painting. Once the racket is free from any imperfections the painting process can start. The process is done in a cabin where the imprinting, painting and laca are applied. Each year, we try to use colours that fit with our customers desires and trends of the season and market.
Decoration. In the cleanest room of the factory they work with water decals. The objective is none other than to create models and designs that are visually impacting and draw attention, that are attractive and interesting for the players.
Tooling. It the only automised process in the factory done by means of CNC (numerical control). Each racket is machined with a different configuration of holes for cosmetics reasons and the mechanics of each model.
Assembly. The last link of the process before the product is finished. In this stage the grip, cap and the cord are added, all by hand.
Currently, the StarVie factory, depending on the model, takes about 10 to 14 days to make one racket. The monthly production total in 2018 is 2,500 units.
QUALITY CONTROL CERTIFICATES, STARVIE FACTORY
In 2017, StarVie received the quality control certificates ISO 14001:2015 and ISO 9001:2015 for their factory in Azuqueca de Henares for design, manufacturing and distribution of padel rackets. Both certificates are valid for 4 years until 2020. The ISO 14001:2015 certifies the system of environmental management of the factory, whilst the ISO 9001:2015 is for the quality systems of the same.
