Hansa Soft Toys: 'Stuffed for Real' - Article by Johannes L. Chua

A toy factory is an unlikely part of a travel itinerary.

But when the President of a Republic and her 'apos' as guests, and Hollywood celebrities such as Oprah and Michael Jackson rave about its products, this factory has not only become a side trip, but a sought-after destination.

The kind of excitement that kids often experience (even if you are a really jaded adult) builds up especially when you enter the reception area where a life-size giraffe welcomes you. And you are nowhere near a jungle or a safari because you are inside the Clarkfield Export Zone in PamPanga.

Hansa Toys International has been in the Philippines for the past 12 years and employs more than 300 workers. It has been producing an average of 3,000 animal toys a day with 4,000 variants being exported to 21 countries worldwide.

Part of the allure of Hansa soft toys is the life-like quality that each animal has. Each one – from the smallest rat to the gigantic elephant – is made using the actual animal characteristics and dimensions of that living creature. And Filipino workers make them come 'alive' with a stroke of an air brush or paint.

"We were one of the first investors here in Clark and the main factor why we are here is the artistic talent of the Filipinos," said Hans Axthelm, managing director and CEO of Hansa. "It also helped that the Filipinos can speak very good English."

Hans said that Hansa originated in 1972 and is based in Australia. Originally manufacturing educational toys, Hansa ventured into the production of plush toys. Since then, Hansa has been known as the global leader in realistic animal plush products.

Because of this, Hans revealed that the Hansa soft toys are quite expensive but "reasonable considering the quality and time that goes into creating each one." Prices range from $10 to $50,000.

Hansa products are not sold in the Philippines though. "The pricing is not geared for Filipino consumers," said Hans.

Don't fret though, each product is labelled 'Made in the Philippines' and enough recognition to the ingenuity is achieved of the Filipino worker since Hansa products grace the rooms of royalties, dignitaries, celebrities and the rich and famous.

If you wanted to have your own collection of Hansa animal soft toys, and can globe-trot anytime of the day, visit the toy shops of Russia, Ukraine, France, England, US, Korea, Canada, Australia, Qatar, Kuwait, Spain and Italy.

"These countries are where the demand of Hansa is very high. Sometimes, we can't even supply enough. The workers sometimes even work on Sundays," said Hans who revealed that their clients are not one-time buyers but are mostly collectors.

"There's even a Hollywood actress who said that she has a room full of Hansa toys," enthused Hans.

The 'secret' of Hansa lies in the meticulous research and quality control the company implements.

"We have designers and our own research and development department that make sure that each colour, spot or stripe on an animal's skin is carefully and correctly reproduced," he said.

The materials of Hansa soft toys are 40 percent Philippine-made and 60 percent imported. The stuffing of each animal is synthetic fibre polyester making it washable and safe to hug (and sleep with).

"We analyse each fabric and find out what's closest to the animal skin. For example, we find out how much black and white a zebra has. Then we put a sample under the spectrometer to find out the exact composition. We measure the fibres, the thickness of the animal skin and then reproduce it," he said. "I think we are the only one in the world to do it this meticulously."

Hans revealed that the most popular of the Hansa toys is the giraffe with some customers buying the life-size 18 foot animal.

The production process is not that easy, told Hans. After all the specifications are studied, fabrics analysed and materials sourced, only then can the sewing process start.

"Each item consists of anything from 40 to 80 pieces. Each operator has to remember which piece goes where," said Hans. "This is where I count on the skills of the Filipino workers."

After this stage, the product goes to the eye-setting department. "Basically, this is where they put the eyes of the animal, and the 'life' into each item," said Hans.

Then it goes to the stuffing and finishing stage. "This is where the sculpturing happens. For the big animals, there will be a metal frame to stabilise it," he added.

The finishing department then decorates the animal, paints it by airbrush and ensures quality control. Then it is off to the container where it will travel the seas to reach the posh department stores of the world.

The recent visit of President Gloria Macapagal-Arroyo and her grandchildren in the factory is a testament to the wide appeal of the Hansa soft toys; that even powerful men and women rediscover the 'child' in them.

"Her supposed-to-be 30 minute tour of the facilities was extended to about 2 hours," said Hans who described President GMA as "wonderful."

"The President was very surprised and also amazed at what we do here. Full credit must be given to her economic policies and the way she actually mixes with the people. She recognised the artistic talent that can only be found in Filipino workers," revealed Hans. "She was visibly proud."

Article by Johannes L. Chua