ZAGO Moulds Solutions: Mastering the Art of PU Injection for Over 60 Years

For more than six decades, ZAGO Moulds Solutions has been shaping the future of footwear moulding with precision, innovation, and passion. From the very beginning, the company has understood that true excellence in mould making is not just about technology, but about mastering the details — from air bubbles to flashes — that define the quality of the final product.

Burrs and Bubbles: The True Challenge of Mould Making

“Knowing how to create the best conditions to keep the air inside the material and to expel the air trapped on the edges of the mould: this is the essence of today’s mould maker’s work,” explains Giorgio Zago, CEO and son of the company’s founder.

In footwear moulding, burrs and bubbles are the ultimate test. On one hand, bubbles are a key feature of polyurethane that make the material lightweight and comfortable. On the other, they can be perceived as imperfections on the sole’s surface. The challenge lies in making them invisible without compromising performance.

For ZAGO, this balance requires a combination of in-depth design studies, advanced technologies, and above all, decades of craftsmanship.

A Family Legacy Forged in Innovation

Founded in 1958 by Elio Zago, the company has grown from a small workshop into one of the world’s leading producers of footwear moulds. Elio himself liked to describe mould makers as “sculptors of today,” comparing the long journey from clay to bronze statues in the Renaissance to the modern path from concept to finished mould.

This philosophy of blending artistry and engineering continues to drive ZAGO. Over two generations, the company has built a reputation for reliability, exporting 50% of its production to Europe, 30% worldwide, and 20% within Italy.

Polyurethane: Lightweight, Versatile, High-Performing

At the heart of ZAGO’s success is its specialisation in PU injection moulds. While polyurethane is more expensive than rubber or PVC, it offers unmatched benefits:

• Exceptional lightness (second only to EVA)

• High comfort levels for long-term wear

• Versatility across different footwear categories

On a molecular level, polyurethane’s reduced weight comes from gas trapped during injection, forming air bubbles within the foam. This makes footwear not only lighter but also more comfortable — a crucial feature for professional and high-performance shoes.

Meeting the Needs of Every Sector

ZAGO’s moulds serve a wide range of footwear applications, including:

• Safety footwear for construction, mining, engineering, and military use

• Trekking footwear for rough and uneven terrains

• Casual shoes for everyday urban wear

• Outdoor sport footwear, designed for stability, cushioning, grip, and waterproofing

Each mould is the result of meticulous study, testing, and design refinement, ensuring that clients receive solutions tailored to their specific needs and industries.

Research, Study, and Dedication: The ZAGO Way

The story of ZAGO is one of research and dedication, where every mould undergoes a journey of continuous improvement. As Giorgio Zago notes, designing effective moulds is not about shortcuts — it’s about combining engineering precision with artisanal know-how, letting expertise and passion guide the process.

From burrs and bubbles to flawless soles, every step reflects the company’s mission: to deliver moulds that guarantee healthy, safe, and comfortable walking in every environment, from construction sites to mountain trails.

Conclusion: Excellence Forged in Generations

With over 60 years of history and two generations of leadership, ZAGO Moulds Solutions has perfected the art of PU injection moulds. By mastering the fine details that others might overlook, the company ensures its clients receive not just moulds, but high-performing, long-lasting solutions that set new standards in the global footwear industry.

Ready to bring precision and innovation into your footwear production? Partner with ZAGO Moulds Solutions and discover the power of excellence forged over generations.