At Kalsi Cords, we’ve been manufacturing high-quality cords, braids, elastics and shoelaces for decades. While many people use shoelaces every day, very few know what goes into producing a durable, reliable lace.
Whether you’re a footwear brand, promotional company or retailer looking for bespoke shoelaces, understanding the manufacturing process can help you appreciate the quality behind every pair.
Step 1 – Selecting the Right Yarn
Every quality shoelace starts with choosing the correct yarn.
Different applications require different materials, including:
- Polyester – durable, colourfast and ideal for everyday footwear
- Cotton – soft with a natural finish
- Recycled polyester – a more sustainable option
- Waxed cotton – commonly used on formal and dress shoes
The yarn selected affects the appearance, strength, flexibility and lifespan of the finished lace.
Step 2 – Braiding or Weaving
The yarn is then fed into specialist braiding or narrow fabric machines.
This stage determines whether the lace will be:
- Flat
- Round
- Tubular
- Fashion braid
- Heavy-duty work boot lace
Machine settings control the density, flexibility and diameter, ensuring every production run is consistent.
Step 3 – Colour Matching
For bespoke orders, colour is everything.
We can manufacture shoelaces in a wide variety of colours to match brand guidelines, footwear collections or seasonal designs.
This allows footwear manufacturers and fashion brands to create a completely coordinated product.
Step 4 – Cutting to Length
Once manufactured, the continuous braid is cut and tagged into precise lengths.
Common shoelace lengths include:
- 60 cm
- 75 cm
- 100 cm
- 120 cm
- 140 cm
- Longer lengths for boots and specialist footwear
The correct length depends on the number of eyelets and the style of shoe.
Step 5 – Applying the Aglets
The plastic or metal tips found on each end of the lace are known as aglets.
Although small, they’re one of the most important components because they:
- Prevent fraying
- Make threading easier
- Improve durability
- Give the lace a professional finish
Aglets can also be customised in different colours or finishes to suit premium footwear brands.
Step 6 – Quality Control
Every production batch is inspected before dispatch.
Checks typically include:
- Length accuracy
- Colour consistency
- Tensile strength
- Braiding quality
- Finish of the aglets
Maintaining consistent quality ensures every pair of shoelaces performs exactly as expected.
Made in Britain
As a UK Manufacturer, Kalsi Cords supplies bespoke shoelaces to businesses across numerous industries.
Working directly with a manufacturer offers several advantages:
- Faster lead times
- Lower minimum order quantities
- Bespoke colour matching
- Consistent quality
- Direct technical support
Whether you require shoelaces for fashion, footwear, workwear, sports shoes or promotional products, manufacturing in the UK provides greater flexibility and reliability.
Looking for Custom Shoelaces?
If you’re searching for a trusted UK manufacturer of bespoke shoelaces, Kalsi Cords can help.
From standard replacement laces to completely customised designs, our experienced team can manufacture shoelaces to your exact specification.
Contact Us today to discuss your requirements and discover how our manufacturing expertise can support your next project.
