'Jabulani', Official Match Ball of the 2010 FIFA World Cup



General views of the production
Production process - Pre-products delivered to Longway factory 1. TPU (transparent) 2. EVA 3D panels (white) 3. Bladder including valve (orange) 4. Polyester/cotton fabric (white) 5. Various inks (11 colours), various types of glue 6. Latex compound A Carcass – the ball chassis: 1. Fabric machining (three steps on one machine) a. Stretching b. Fabric lamination with latex c. Drying 2. Automatic cutting of the panels 3. Stitching of the carcass 4. Metal detection 5. Turning carcass 6. Weighing of carcass and bladder 7. Insert bladder and gluing of the valve 8. Carcass shaping 9. Spray coating of the latex adhesive onto the carcass 10. Drying of the carcass in a hot channel Carcass ready for final assembling B EVA 3D Panels (4 tripods and 4 triangles): 1. EVA cutting (triangles and tripods) 2. UV-treatment (cleaning process) 3. Panel wall cementing 4. Top side cementing EVA ready for the high-frequency vacuum forming with the TPU C TPU (delivered as roll): 1. TPU sheet cutting (automatic rolling up and cutting) 2. Heat-transfer the FIFA World Cup™ logo on TPU 3. Flame treatment of the TPU 4. TPU printing line a. Place TPU films onto the print conveyor b. Underglass printing of 11 different colours c. Stripping of the printed TPU film (final ball design) 5. Cutting and inspection of the 8 different TPU pieces 6. TPU films pin hole cutting (CCD hole punching) 7. 3D vacuum forming of the TPU films a. Preparation (apply films on plate) b. Vacuum forming c. Detach films TPU is ready for high-frequency vacuum forming with the EVA D High-frequency vacuum bonding of TPU and EVA 1. Stock fitting EVA and TPU 2. High-frequency vacuum bonding process 3. Trimming of the final panels 4. Automatic panel cleaning/gluing/drying process a. Triangle panels 1. Cleaning 2. apply glue 3. drying b. Tripod panels 1. Cleaning 2. apply glue 3. drying Panels are ready for assembling E Final ball assembling: 1. Valve hole punching (valve tripod panel) 2. Assemble two ball halves out of 4 panels each 3. Weighing two halves (assembled ball panels) and carcass (ideal weight 440 g) 4. Centring of the valve on the carcass 5. Pre-forming of the carcass and the two ball halves (transparent mould) 6. Bonding with air-pressure mould (blue single mould) 7. Thermal bonding in heated moulds 8. Chilling in cooling tunnel 9. Balls rolling out for a final 24 hrs storage / conditioning Final inspection (weight, circumference, roundness, pressure, visual check of gluing, texture, aero grooves and graphics) and packaging for shipping.
This media asset is free for editorial broadcast, print, online and radio use. It is restricted for use for other purposes.


  • Georg Kovacic
    Director Brand-Activation PR Austria
    +43 01 7 990 28 915
    +43 664 2119 022