Our production steps

Each figurine is meticulously handcrafted and has to pass a series of rigorous quality tests before returning to the customer as an item ready for sale.

Mold making

Mold making

Our mold shop specializes in hand-made mold cavities, which give us the ability to accurately and realistically replicate surface textures. We manufacture both modeled prototypes and computer generated 3D Sculptures. Our skills include everything from steel casting to digitally controlled 3D steel mold printing. The machinery required for this purpose is continuously kept at the latest state of the art.

Mold making
Mold making
Mold making
Mold making
Mold making
Mold making
Injection molding

Injection molding

Our injection molding department comprises of 50 modern Arburg machines with clamping forces ranging from 120 to 500 tons. The entire department is controlled by a computer based central planning and control system, ensuring the greatest possible efficiency and utilization of the machines. The first visual inspection of many quality controls is done during the manual demolding of the figures, in order to minimize potential subsequent product defects.

Injection molding
Injection molding
Injection molding
Injection molding
Injection molding
Injection molding
Airbrush

Airbrush

Our trained employees handle the fine nozzles of their spray guns with meticulous dexterity to give the figures the necessary lifelike shading and color gradients making each figure a unique specimen. With a total of 150 spray booths, we can work in two shifts.

Airbrush
Airbrush
Hand painting

Hand painting

Each figure is crafted by hand. The painters use minimal machinery in order to give the figures a lifelike appearance with each brush and paint stroke. Each figure also has to pass a series of rigorous quality tests before it is delivered as an item ready for sale.

Hand painting
Hand painting
Hand painting
Hand painting
Hand painting
Hand painting
Tampoprint

Tampoprint

We have 20 tampoprint machines at our disposal to give the figures that require a particular treatment, using special patterns, inscriptions, logos or pictures, an exceptional look. We have mastered the unique techniques and have decades of experience in this production technology.

Tampoprint
Tampoprint
Tampoprint
Thermal transfer

Thermal transfer

Multicolored and detailed motifs as well as logos and images can be brilliantly recreated by our thermal transfer printing masks that can be applied to the figures. This technology provides the customer with many new design options.

Thermal transfer
Ultrasonic welding

Ultrasonic welding

Through this type of welding are able to turn several components into a safe end product without the use of adhesives. Many international companies use this technique to securely seal their products.

Ultrasonic welding
Blister packing

Blister packing

Different markets require different packaging techniques. To meet international packaging guidelines, we work with fully automatic blister machines, allowing us to pack your products cost effectively in secure retail packaging without restricting the sale promoting visibility of the product.

Blister packing unicorn figurine
Blister packing elves figurine
Blister packing rider figurine
Blister packing riding set figurine
Blister packing wildlife figurine
Testing

Testing

Each figurine has to pass a series of rigorous quality tests before it is shipped as an item ready for sale. The quality of the figures is tested at our special test facilities. This happens both internally by trained personnel, as well as externally by testing companies (UL Laboratory, SGS, TÜV-Rheinland, etc.). This enables us to meet the numerous, internationally varying safety standards for children's toys.

Testing
Testing
Testing
Testing
Testing

Value Added

From design to product.

Our value creation follows certain processes, passes through different departments and follows a strict timeline. Below you will find an exemplary production flow of an order.

Delivery - 2 days

Due to the close connection to Europe, we are able to offer our customers efficient warehouse planning through reliable just-in-time production. As a rule, our carriers are on the road for only two days until the goods reach us and are available for further processing.
Lieferung

Product development - 14 days

Our designers work both with the latest 3D animation software and with their own hand sketches. Each figure starts with a stroke and ends as an expressive animal, figurine, elf, knight, mascot, or any other imaginable character. We are also happy to offer you our entire scope of service from design to finished product.
Produktentwicklung

Mold making - 20 days

Our expert staff, trains according to German curricula, to design and manufacture custom molds for injection molding. Tunisia has a closed infrastructure with its own training centers in mold making. Together with our customers, our employees provide assistance for a wide range of projects.
Mold making

Injection molding - 10 days

We work with new German machines from Arburg and are therefore able to cover all customer requirements. Our specialization lies in the processing of PVC, because based on our 30 years of industry experience.
Injection molding

Hand painting - 20 days

Our core competence lies in the decoration of figures using paints and brushes. With meticulous care, our employees can follow specification patterns and develop a high quality standard product using their experience and efficiency. This has qualified us to be a market leader in the international market.
Hand painting

Paint spraying - 5 days

We aguement our painting process with our airbrush techniques. As with body painting, we can give our figures shading, transitions and effects that make the look even more naturalistic. Through complicated and well thought-out sequences of work steps, we create lovely play figures that are close to their real-life counterparts.
Farbspritzen

Tampoprint – 2 days

Our Tampoprint department supports and optimizes our hand painting and air brush departments. We work with ten machines in four-color printing to offer our customers better quality in addition to greater efficiency.
Tampoprint

Packaging - 2 days

From simple transport packaging to decorative sales packaging, we support our customers. Through our local partners in Tunisia, we can develop and offer everything from labels to colorful sales cartons at low cost based on our previous experience.
Verpackung

Export – 2 days

Likewise to our import logistics, our customers also benefit from the short routes to Europe for exports. If desired, we are able to offer country specific packaging and ship accordingly.
Export