S1 Safety shoes

e.s. Zembra

From First Prototype to Final Production Model

In just about a year, an idea becomes a certified safety shoe made in Germany.

How many development steps did my favourite shoes go through before hitting the job site? Who ensures they protect my feet under the toughest conditions? Take a look behind the scenes of our development and manufacturing process – using the S1 safety low shoes e.s. Zembra as an example.

From first idea to bestseller in the store

#1 The Initial Idea

Our designers give early concepts a face with sketches and 3D models. They combine functional requirements with modern product design and years of expertise in safety footwear. With an eye for detail, the foundation is laid for everything that follows.

#2 The Prototype

Our team holds the first version of the S1 model e.s. Zembra in their hands. But this first prototype is just the beginning. Until the fit and shape are just right, the design will be refined and optimised multiple times.

#3 The Stress Test

Before the e.s. Zembra is certified as an S1 safety shoe, it goes through intensive testing in our in-house Test Centre. Among other things, the toe cap, flex performance, durability, and slip resistance of the sole are tested under EN ISO 20345 standard conditions.

#4 Certification by an External Testing Institute

Now the e.s. Zembra leaves the CI Factory for the first time: We send our development to an independent testing institute for certification in accordance with EN ISO 20345. There, it proves its worth and passes all required tests with flying colours! From now on, it can officially carry the name S1 safety shoe e.s. Zembra.

#5 Market-Ready

Roughly one year after the first concept: The S1 safety low shoes e.s. Zembra are ready for production! 30 team members were involved across 23 development steps. They are manufactured in our German CI Factory using efficient direct soling. This method ensures a particularly strong bond between sole and upper – no adhesives required.

Flex Test According to
DIN EN ISO 20344

The outsole of a work shoe must remain functional under repeated stress without breaking or becoming brittle. In the flex test conducted at our Test Centre, the e.s. Zembra performs far above standard: While EN ISO 20345 requires 30,000 flexes, the S1 model endures over 100,000!

ESD Features
According to DIN EN 61340

The S1 safety low shoes e.s. Zembra are ideal for anyone working with sensitive electronics. In our Test Centre, we examine the ESD functionality to ensure the shoes protect delicate electronic components from electrostatic discharge – in full compliance with standards.

Certified Toe Protection
According to EN 22568

Thanks to their 100% metal-free, carbon fibre-reinforced toe cap, the S1 safety shoes e.s. Zembra are pleasantly lightweight without compromising on protection. In the lab, the toe cap is subjected to compression. The space beneath the cap must not deform beyond the limits set in EN 22568 – to ensure your toes are fully protected.

Slip Resistance
According to DIN EN 20344

The e.s. Zembra features a robust, slip-resistant sole. At our Test Centre, its grip is tested under realistic conditions – on ceramic tiles with a diluted soap solution.

Make it Personal!

Our Tech – Your Vision

Those who do great work should show it off with pride. Identity, visibility, team spirit – take your brand to the next level with perfectly placed custom logos. Browse the following pages for inspiration on shoe customisation and reach out to us directly: Our experts are here to make your ideas a reality.

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