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TECHNIQUE

Our commitment to genuine leather development

SPECIALTY

We create user-friendly products that put our customers at ease, drawing from data generated from both our engineers’ experience and intuition, and the properties of leather itself. Leather has been used throughout human history. However, because it is a natural material, it carries boundless, untapped potential. Our belief in the potential of leather drives our unwavering commitment to R&D. Our standards of quality consistently exceed expectations.

Manufacturing Process

①Hot-water soakingOur tanned hides (known as “wet blue”) are imported from overseas. The hides then undergo a lengthy process to restore them to a fresh state. After squeezing out excess water, we shave the undersides to a certain thickness according their intended use.

①Hot-water soaking

Our tanned hides (known as “wet blue”) are imported from overseas. The hides then undergo a lengthy process to restore them to a fresh state. After squeezing out excess water, we shave the undersides to a certain thickness according their intended use.
②Retanning and drum dyeingThen, the hides are scientifically processed to achieve the right softness for their intended use, and to confer properties such as color. The hides are retanned using tannins and undergo a softening process using fatliquors. Dyeing is performed to add color.

②Retanning and drum dyeing

Then, the hides are scientifically processed to achieve the right softness for their intended use, and to confer properties such as color. The hides are retanned using tannins and undergo a softening process using fatliquors. Dyeing is performed to add color.
③DryingA drying process is then performed to set and stabilize the retanning agents and dye. Before drying, hides go through an initial moisture-removal process. Subsequent stages leading up to texture adjustment use a drying method suitable to the leather’s intended use.

③Drying

A drying process is then performed to set and stabilize the retanning agents and dye. Before drying, hides go through an initial moisture-removal process. Subsequent stages leading up to texture adjustment use a drying method suitable to the leather’s intended use.
④Crust inspectionIn-process inspections are performed on all hides that have been completed up to the pre-coating “base” state. These inspections ensure that our hides meet the thickness, texture (softness), color, surface condition, and other criteria determined for each intended use.

④Crust inspection

In-process inspections are performed on all hides that have been completed up to the pre-coating “base” state. These inspections ensure that our hides meet the thickness, texture (softness), color, surface condition, and other criteria determined for each intended use.
⑤CoatingA coating is applied to the completed base surface. The final color, gloss adjustment, and functional properties such as durability and anti-soil treatments are applied in this stage.

⑤Coating

A coating is applied to the completed base surface. The final color, gloss adjustment, and functional properties such as durability and anti-soil treatments are applied in this stage.
⑥TexturingAdjustments are made to restore the leather to its original texture, removing the warmth and moisture added in the coating stage.

⑥Texturing

Adjustments are made to restore the leather to its original texture, removing the warmth and moisture added in the coating stage.
⑦Product inspectionInspections are performed on all pieces of leather to ensure that they meet the criteria for the final product. These inspections ensure that the condition of each product meets the color, gloss, thickness, texture, and shape criteria for its product type.

⑦Product inspection

Inspections are performed on all pieces of leather to ensure that they meet the criteria for the final product. These inspections ensure that the condition of each product meets the color, gloss, thickness, texture, and shape criteria for its product type.
⑧CuttingThe finished leather product is cut to the shape requested by the customer. Each individual leather product is checked for scratches and flaws, which are marked by hand. These marked locations are avoided during cutting. Our cutting method uses both a die cutting machine and a high-speed, high-performance automatic cutting machine.

⑧Cutting

The finished leather product is cut to the shape requested by the customer. Each individual leather product is checked for scratches and flaws, which are marked by hand. These marked locations are avoided during cutting. Our cutting method uses both a die cutting machine and a high-speed, high-performance automatic cutting machine.
⑨Final inspectionAll parts of the cut leather are inspected. During inspections, we check whether the appearance and shape of each part are within the limits agreed upon with the customer.

⑨Final inspection

All parts of the cut leather are inspected. During inspections, we check whether the appearance and shape of each part are within the limits agreed upon with the customer.

Challenging ourselves to develop new surface materials
(such as those with functional properties)

LABORATORY

When it comes to synthetic leather, we think outside the box, always challenging ourselves to develop innovative surface materials. During the initial prototyping in our laboratory, we use original mixing and coating techniques and cutting-edge analysis tools to develop highly functional and sustainable surface materials. We welcome the challenge of bringing exciting new facets to our customers’ everyday lives.

Decorative techniques

DECORATION
We are constantly researching and developing decorative techniques that bring out the appeal of our surface materials. We use a variety of processing methods to meet your needs, including perforation, which combines aesthetic design and functionality, and high-precision quilting. We seek new ways to express the qualities of our surface materials to their fullest potential by leveraging their unique properties.

Decorative techniques

①Repeat perforationPerforation is the process of making holes in the leather. This adds not only design value, but also functional properties such as breathability. Repeat perforation punches a consistent pattern into the leather using parallel pins.

①Repeat perforation

Perforation is the process of making holes in the leather. This adds not only design value, but also functional properties such as breathability. Repeat perforation punches a consistent pattern into the leather using parallel pins.
②Controlled perforationUnlike repeat perforation, this perforation process is computer-controlled, enabling complex designs that were previously impossible.

②Controlled perforation

Unlike repeat perforation, this perforation process is computer-controlled, enabling complex designs that were previously impossible.
③QuiltingThree-dimensional designs can be applied to the leather by attaching a backing material to the underside of the leather, then sewing straight and curved lines. Combined with perforation processing, this further expands the range of possible designs.

③Quilting

Three-dimensional designs can be applied to the leather by attaching a backing material to the underside of the leather, then sewing straight and curved lines. Combined with perforation processing, this further expands the range of possible designs.
④EmbossingUsing a welder to emboss the leather enables the application of a wider variety of three-dimensional designs.

④Embossing

Using a welder to emboss the leather enables the application of a wider variety of three-dimensional designs.
⑤EmbroideryBy embroidering the leather surface, we can add pictures and letters to the design.

⑤Embroidery

By embroidering the leather surface, we can add pictures and letters to the design.

Surface-processing techniques

DECORATION
We are developing techniques to deliver safe, hassle-free surface materials to our customers. These techniques can be used to apply coatings to both genuine and synthetic leather. Our surface materials are processed to enhance their quality. The use of coating techniques improves both the feel and physical properties of the material.
CONTACT

Head Office and Yamagata Plant
57-1 Sansha, Yamagata City,
Yamagata Prefecture 990-0898
Tel: +81 23 684 4311 (representative)
Fax: +81 23 684 4317

Tokyo Office
Midori Anzen Building 4th Floor,
5-4-3 Hiro-o, Shibuya-ku, Tokyo 150-8455
Tel: +81 3 3442 2349 (representative)
Fax: +81 3 3442 2369

Midori Autoleather Japan Site since 2012-04-28　
Copyright 2018 Midori Auto leather Co.,Ltd.. All Rights Reserved.
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