When Alejandro Valverde crossed the line first to win the World Championship road race in Innsbruck last weekend, the staff at Endura, which supplies his Movistar team, knew that they had a race of their own to run.
With the Spaniard due to race in Italy in the coming days – Valverde is down to ride the Tre Valli Varesine on Tuesday and il Lombardia next Sunday, and may also race Wednesday’s Milan-Turin – the Livingston-based business had just one week to design and produce his rainbow jersey.
Here Endura recounts the processes that resulted in the kit that the new world champion will debut on Tuesday being designed, signed off and produced.
As soon as Alejandro Valverde crossed the line with arms aloft as the new UCI Road World Champion last Sunday, the cogs of the finely tuned machine that has supplied technical clothing to Movistar Team since 2014 began to turn almost as soon as Bala’s wheels drew to a stop beside the podium.
In a series of Whatsapp messages and emails between team and their expert tailors back in Scotland on Sunday evening, a plan of attack was agreed with #EnduraCustom even as Valverde was celebrating his magnificent victory in the Austrian Tirol. The plan – to produce kit worthy of a World Champion. Of course, Endura are no strangers to manufacturing rainbow jerseys, having recently produced MTB versions for Rachel Atherton and Kade Edwards (Trek Factory Racing DH) and previously for para-cycling World Champion Denise Schindler.
Unlike some pro team’s clothing suppliers, Endura make kit end-to-end in-house by the same production team that produce over 50,000 garments a year for clubs and teams worldwide. This is no development lab, it’s a proper factory, employing around 60 staff, all based in Livingston, near Edinburgh. Movistar Team’s kit designer Stuart Kirk kicked off the production process first thing on Monday by consulting UCI’s fascinating technical documents on kit design, before producing some initial designs for approval by Endura management, then Movistar Team and then the UCI.
Production Shot 3 (Image Credit: Farrelly Atkinson)
When the design was signed off then the clock started ticking in earnest. Patterns were placed on layers of fabric to be run through Endura’s automated cutting table to create the eleven panels that make up a team issue jersey (and twelve more for the bibshorts). Meanwhile, Stuart Laidlaw’s print shop team were watching the design edging through their large format printer, ready to be passed on to the heat pressing team next door.
Production Shot 5 (Image Credit: Farrelly Atkinson)
If you’ve not seen dye sublimation printing in action, it can resemble a form of magic as a mix of heat and pressure transfers hi-tech inks from printed sheets straight into the fabric itself. No further treatment is required to make the panels colourfast. Just one further step is necessary for Movistar Team’s kit with parts of the jersey heading a few work stations along to have Endura’s proprietary Surface Silicone Topography technology applied by a small crew of specialist technicians.
Production Shot 7 (Image Credit: Farrelly Atkinson)
The whirring sewing machines used by expert machinists have been the beating heart of Endura since the company was founded 25 years ago and some of them have been with the Scottish company since the very early days in the small factory that spawned a global brand. Zips are added to jersey panels, pockets are created and Alejandro’s favoured 700-series pad is sewn into the bibshorts before heading down the line for a QC check under the watchful gaze of Operations Director Alison Moodie.
Production Shot 8 (Image Credit: Farrelly Atkinson)
From start to finish the entire process took less than the 6 hours and 46 minutes that it took Alejandro to win his World Championship, but as modest Scots, the team at Endura wouldn’t like to boast just how quickly they can produce an outfit for a World Champion.
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Simon joined road.cc as news editor in 2009 and is now the site’s community editor, acting as a link between the team producing the content and our readers. A law and languages graduate, published translator and former retail analyst, he has reported on issues as diverse as cycling-related court cases, anti-doping investigations, the latest developments in the bike industry and the sport’s biggest races. Now back in London full-time after 15 years living in Oxford and Cambridge, he loves cycling along the Thames but misses having his former riding buddy, Elodie the miniature schnauzer, in the basket in front of him.
15 Comments
15 thoughts on “Endura reveal how they made Alejandro Valverde’s rainbow jersey”
Quite possibly the only
Quite possibly the only positve story associated with Valverde’s WC win.
Would Jim McFarlane of Endura care to comment on Brexit as he said that some Endura production would move to europe if Scotland voted for independence in 2014 ? Now that “we” are leaving the EU will Endura be moving production abroad or not, or was that just a scare story for his employees to make sure they didn’t vote for independence ? Mr McFarlane has been very quiet about Brexit
Would Jim McFarlane of Endura care to comment on Brexit as he said that some Endura production would move to europe if Scotland voted for independence in 2014 ? Now that “we” are leaving the EU will Endura be moving production abroad or not, or was that just a scare story for his employees to make sure they didn’t vote for independence ? Mr McFarlane has been very quiet about Brexit
— dreamlx10
Scotland gaining independance is a massive different kettle of fish compared to the UK leaving a closed shop terrorist sponsoring dictatorship that has a negative effect on trade and finances for the UK. Scotland leaving the union would lead to poverty in Scotland even worse than Holyrood has already imparted on its citizens (whilst blaming everyone except themselves), health levels would continue to drop, services would be utterly fucked, taxes would go up hugely but yeah, have a pop at an independant based on a ludicrous comparison.
Oh what, you think the dwindling oil tax revenue will bail Scotland out, yeah because fields like Clair that are knocking out 60,000 barrels (compared to brent at 200million peak and still despite been closed down in the next decade is still producing 1M BPD) will prop up a government that has proven to be worse than the Tories!
Would Jim McFarlane of Endura care to comment on Brexit as he said that some Endura production would move to europe if Scotland voted for independence in 2014 ? Now that “we” are leaving the EU will Endura be moving production abroad or not, or was that just a scare story for his employees to make sure they didn’t vote for independence ? Mr McFarlane has been very quiet about Brexit
— BehindTheBikesheds
Scotland gaining independance is a massive different kettle of fish compared to the UK leaving a closed shop terrorist sponsoring dictatorship that has a negative effect on trade and finances for the UK. Scotland leaving the union would lead to poverty in Scotland even worse than Holyrood has already imparted on its citizens (whilst blaming everyone except themselves), health levels would continue to drop, services would be utterly fucked, taxes would go up hugely but yeah, have a pop at an independant based on a ludicrous comparison.
Oh what, you think the dwindling oil tax revenue will bail Scotland out, yeah because fields like Clair that are knocking out 60,000 barrels (compared to brent at 200million peak and still despite been closed down in the next decade is still producing 1M BPD) will prop up a government that has proven to be worse than the Tories!
Would Jim McFarlane of Endura care to comment on Brexit as he said that some Endura production would move to europe if Scotland voted for independence in 2014 ? Now that “we” are leaving the EU will Endura be moving production abroad or not, or was that just a scare story for his employees to make sure they didn’t vote for independence ? Mr McFarlane has been very quiet about Brexit
— Duncann
Scotland gaining independance is a massive different kettle of fish compared to the UK leaving a closed shop terrorist sponsoring dictatorship that has a negative effect on trade and finances for the UK. Scotland leaving the union would lead to poverty in Scotland even worse than Holyrood has already imparted on its citizens (whilst blaming everyone except themselves), health levels would continue to drop, services would be utterly fucked, taxes would go up hugely but yeah, have a pop at an independant based on a ludicrous comparison.
Oh what, you think the dwindling oil tax revenue will bail Scotland out, yeah because fields like Clair that are knocking out 60,000 barrels (compared to brent at 200million peak and still despite been closed down in the next decade is still producing 1M BPD) will prop up a government that has proven to be worse than the Tories!
— BehindTheBikesheds
I don’t like the term “gammon” but…
— dreamlx10
If his reply to me isn’t a wind up then I’m happy to use the term “gammon” in relation to the very angry man called Behind The Bin Sheds
Would Jim McFarlane of Endura care to comment on Brexit as he said that some Endura production would move to europe if Scotland voted for independence in 2014 ? Now that “we” are leaving the EU will Endura be moving production abroad or not, or was that just a scare story for his employees to make sure they didn’t vote for independence ? Mr McFarlane has been very quiet about Brexit
— Duncann
Scotland gaining independance is a massive different kettle of fish compared to the UK leaving a closed shop terrorist sponsoring dictatorship that has a negative effect on trade and finances for the UK. Scotland leaving the union would lead to poverty in Scotland even worse than Holyrood has already imparted on its citizens (whilst blaming everyone except themselves), health levels would continue to drop, services would be utterly fucked, taxes would go up hugely but yeah, have a pop at an independant based on a ludicrous comparison.
Oh what, you think the dwindling oil tax revenue will bail Scotland out, yeah because fields like Clair that are knocking out 60,000 barrels (compared to brent at 200million peak and still despite been closed down in the next decade is still producing 1M BPD) will prop up a government that has proven to be worse than the Tories!
— BehindTheBikesheds
I don’t like the term “gammon” but…
— dreamlx10
Hahahaha, whatever dropkick, calling me a gammon shows you up for the fuclwit you are.
Would Jim McFarlane of Endura care to comment on Brexit as he said that some Endura production would move to europe if Scotland voted for independence in 2014 ? Now that “we” are leaving the EU will Endura be moving production abroad or not, or was that just a scare story for his employees to make sure they didn’t vote for independence ? Mr McFarlane has been very quiet about Brexit
— BehindTheBikesheds
Scotland gaining independance is a massive different kettle of fish compared to the UK leaving a closed shop terrorist sponsoring dictatorship that has a negative effect on trade and finances for the UK. Scotland leaving the union would lead to poverty in Scotland even worse than Holyrood has already imparted on its citizens (whilst blaming everyone except themselves), health levels would continue to drop, services would be utterly fucked, taxes would go up hugely but yeah, have a pop at an independant based on a ludicrous comparison.
Oh what, you think the dwindling oil tax revenue will bail Scotland out, yeah because fields like Clair that are knocking out 60,000 barrels (compared to brent at 200million peak and still despite been closed down in the next decade is still producing 1M BPD) will prop up a government that has proven to be worse than the Tories!
While not a enthusiastic supporter of Scottish independence, the idea that I would be independent from BTBS views is very attractive.
We could have a country of nuance and subtlety, where disc brakes could be used for appropriate bike builds and helmet wearing would be a choice.
If the choice is between Crobyn and May (or Boris) to bring prosperity, look after the NHS etc, then maybe it couldn’t be worse (though I have no desire for IndyRef2 at the monent).
While not a enthusiastic supporter of Scottish independence, the idea that I would be independent from BTBS views is very attractive.
We could have a country of nuance and subtlety, where disc brakes could be used for appropriate bike builds and helmet wearing would be a choice.
If the choice is between Crobyn and May (or Boris) to bring prosperity, look after the NHS etc, then maybe it couldn’t be worse (though I have no desire for IndyRef2 at the monent).
— Sniffer
Whah whah whah. You like others don’t like discussion or criticism, criticism that was unfairly aimed at the owners of Endura in the first instance hence my reposte!
While not a enthusiastic supporter of Scottish independence, the idea that I would be independent from BTBS views is very attractive.
We could have a country of nuance and subtlety, where disc brakes could be used for appropriate bike builds and helmet wearing would be a choice.
If the choice is between Crobyn and May (or Boris) to bring prosperity, look after the NHS etc, then maybe it couldn’t be worse (though I have no desire for IndyRef2 at the monent).
— BehindTheBikesheds
Whah whah whah. You like others don’t like discussion or criticism, criticism that was unfairly aimed at the owners of Endura in the first instance hence my reposte!
— Sniffer
In what way was my criticism of Jim McFarlane (not Endura) unfair ?
@Smoggysteve "Most would happily ride on the roads and be treated with respect by drivers". But people aren't - and as far as I can see they won't be. Not until there is a lot less driving and it's slower around cyclists, and far more people driving have "skin in the game" eg. they sometimes cycle and their friends and family do also.
That's what leads to the model - which is perhaps most advanced in NL - where cycling, walking and driving are all seen as separate normal transport modes. Their needs, vulnerabilities and any dangers to others are considered. And *that* leads to "mix / share when possible, separate when necessary". But "possible" is "where your 10-year old would be safe to cycle unsupervised" - so very few motor vehicles, going slow!
And AFAICS everybody - even "existing cyclists" - is happy with the result. (I dunno about a few pro cyclists - but don't they tend to have training camps in different counties anyway?)
@quiff as an Edinburgh resident I can confidently say he's speaking without moving his lips in one sense:
- while as I noted in a separate comment there *is* now some real separated cycle infra, all the examples i can think of have *at least as much space* for pedestrians.
The rest of the "cycle infra" is essentially similar to the situation in the rest of the UK: eg. bus lanes*, cycle lanes and shared use paths (eg. "build" infra by sticking up a sign).
Edinburgh is one of the places with a moderately extensive network of former railways which have been converted to "shared use" paths (completely motor traffic few). However though shared they are not narrow by UK standards. And this is all effectively a "free extra" for all non- motorised users, not like the "sign a cycle path" where pedestrians do lose space.
I think this all comes from the "popular understanding" of cycling in which ultimately cyclists are the "other". They don't fit "motor vehicle" or "pedestrian" (including wheelchairs on the very rare occasions people think about that).
Thus "cyclists are cheating" in multiple ways! They shouldn't get their own space as "there aren't enough" of them. And "they can just use the road / path".
But being able to *choose* "on the road" or "on the footway" (shared use path) is clearly unfair - nobody else gets to do that!
BUT of course even if they did pick just one of road OR pedestrian space it's still not fair anyway because they're "too slow" for the road (don't pay "road tax" etc...) and "far too fast" for pedestrians...
* Though some existing cyclists may appreciate them when there are few buses, buses and bikes are a very poor mix for several reasons.
Whilst a shame for any employees, their bib shorts had the worst chamois pad I’d ever encountered, utter waste of my money. Even though they were Strava challenge discount purchases, still a waste of money.
@ktache Just go for the TNT Sports only package, £30.99 for a month. Alternatively have you considered experimenting with a VPN for a few pounds, allowing you to sign up for a free stream abroad, e.g. SBS Australia which streams the Tour live? If I didn't have a kind mate's login that's what I'd do!
So, it's now the month of July and I'm going to have to pay to watch the TdF, for one month only. On a tablet unfortunately, as I didn't manage to get a laptop to rig up to the TV, grrr. Just wondering, what package will I have to fork out for? Not wanting to pay for the wrong one...
Not that it sounds like a dealbreaker given the other faults you've identified, but that cable isn't really a "proprietary" cable, four pin magnetic cables like that are quite common on bone-conducting headphones and other devices (my inexpensive smartwatch uses one) and they can be had for £4.99 on UK Amazon.
There was never really anything to say about le col kit. Most of it was alright. Some of it was poorly designed/made. Trying to position yourself as a Rapha competitor whilst always offering 40% or more off doesn't scream premium though.
15 thoughts on “Endura reveal how they made Alejandro Valverde’s rainbow jersey”
Quite possibly the only
Quite possibly the only positve story associated with Valverde’s WC win.
Would Jim McFarlane of Endura
Would Jim McFarlane of Endura care to comment on Brexit as he said that some Endura production would move to europe if Scotland voted for independence in 2014 ? Now that “we” are leaving the EU will Endura be moving production abroad or not, or was that just a scare story for his employees to make sure they didn’t vote for independence ? Mr McFarlane has been very quiet about Brexit
dreamlx10 wrote:
Scotland gaining independance is a massive different kettle of fish compared to the UK leaving a closed shop terrorist sponsoring dictatorship that has a negative effect on trade and finances for the UK. Scotland leaving the union would lead to poverty in Scotland even worse than Holyrood has already imparted on its citizens (whilst blaming everyone except themselves), health levels would continue to drop, services would be utterly fucked, taxes would go up hugely but yeah, have a pop at an independant based on a ludicrous comparison.
Oh what, you think the dwindling oil tax revenue will bail Scotland out, yeah because fields like Clair that are knocking out 60,000 barrels (compared to brent at 200million peak and still despite been closed down in the next decade is still producing 1M BPD) will prop up a government that has proven to be worse than the Tories!
BehindTheBikesheds wrote:
I don’t like the term “gammon” but…
Duncann wrote:
If his reply to me isn’t a wind up then I’m happy to use the term “gammon” in relation to the very angry man called Behind The Bin Sheds
Duncann wrote:
Hahahaha, whatever dropkick, calling me a gammon shows you up for the fuclwit you are.
BehindTheBikesheds wrote:
This is a wind up right ?
If that jersey is made of the
If that jersey is made of the same material as an Enduro jersey I have then I’ve seen tissue paper thats thicker.
^^^ FFS ^^^
^^^ FFS ^^^
I like the term gammon,
I like the term gammon, especially when used like this: “what’s for dinner?”, “Smoked gammon joint, with roasties and seasonal veggies” 🙂
While not a enthusiastic
While not a enthusiastic supporter of Scottish independence, the idea that I would be independent from BTBS views is very attractive.
We could have a country of nuance and subtlety, where disc brakes could be used for appropriate bike builds and helmet wearing would be a choice.
If the choice is between Crobyn and May (or Boris) to bring prosperity, look after the NHS etc, then maybe it couldn’t be worse (though I have no desire for IndyRef2 at the monent).
Sniffer wrote:
Whah whah whah. You like others don’t like discussion or criticism, criticism that was unfairly aimed at the owners of Endura in the first instance hence my reposte!
BehindTheBikesheds wrote:
In what way was my criticism of Jim McFarlane (not Endura) unfair ?
Oh my, there’s some
Oh my, there’s some interesting views in this thread…
I have been very impressed by
I have been very impressed by all of my Endura purchases.