How footballs and other inflatable balls are made
Jalandhar's district portal says inflatable balls make up about 60% of the sports goods made in the city. The same factories make footballs, rugby balls, volleyballs, netballs and handballs on the same lines.
NITI Aayog's 2026 sports equipment report describes three methods. Hand-stitched balls have PU or PVC panels cut and stitched by hand, then the bladder is inserted and the last seam closed. Machine-stitched balls, the bulk of output and mostly entry-level and promotional balls, have panels sewn by machine and only the final seam stitched by hand. Thermo-bonded balls have panels glued and fused under heat and pressure in a mould; the report notes that this reduces water uptake and is used for high-end match balls. It also notes that PU and TPU cover material and EVA foam are largely imported from China.
Under the cover, a ball is a laminate: the outer skin, one or more foam layers and several layers of polyester or cotton backing, bonded together before the panels are cut. A weak laminate shows up later as bubbles, soft spots and a ball that grows out of shape.
IFAB Law 2 and the FIFA Quality marks
| Item | Law 2 requirement (size 5 football) |
|---|---|
| Circumference | 68 cm (27 in) to 70 cm (28 in) |
| Weight at the start of the match | 410 g (14 oz) to 450 g (16 oz) |
| Pressure at sea level | 0.6 to 1.1 atmosphere (600 to 1,100 g/cm²) |
The FIFA Quality Programme sets stricter requirements and licenses three marks: FIFA Quality Pro, FIFA Quality and FIFA Basic. A ball earns a mark by passing seven laboratory tests: weight, circumference, roundness, bounce, water absorption, loss of pressure, and shape and size retention, with Quality Pro tested under more demanding conditions. Law 2 requires balls in FIFA and confederation competition matches to carry one of the marks. The mark is licensed to a brand for a model; a factory cannot add it to an untested ball.
Rugby, volley and netballs follow their own governing bodies' specifications, which you should attach to the order.
What we check on inflatable balls
| Check | How it is checked | What fails |
|---|---|---|
| Pressure, circumference and weight | Inflated to the printed pressure with a calibrated gauge; circumference tape across several axes; weighed | Outside Law 2 or your specification; a large difference between axes |
| Air hold | Sampled balls inflated and re-measured at the end of the inspection day | Noticeable pressure loss; valve or bladder leaks found with soapy water |
| Seams or bonding | Stitch count and tension along each seam; bonded seams flexed and pressed | Open stitches, gaps, seams lifting, glue visible |
| Cover and laminate | Surface checked for bubbles, wrinkles and soft spots; panel colours against the sample | Delamination, bubbles, print off-register or rubbing off |
| Valve | Position, fit and silicone treatment; needle entry | Valve recessed, off-centre or leaking |
| Marks and claims | FIFA mark, size, pressure and material print against the licence and artwork | Mark on an unlicensed model; wrong size or pressure printed |
Common football and inflatable ball defects and how they are classed
| Defect | Typical cause | Class |
|---|---|---|
| FIFA or other licensed mark on a ball not covered by a licence | Artwork copied from another model | Critical (legal and brand risk) |
| Ball does not hold air | Bladder seam or valve fault | Major |
| Circumference or weight out of specification | Panel cutting, laminate weight | Major |
| Open or broken seam stitches | Loose hand stitching, weak thread | Major |
| Bubbles or delamination in the cover | Poor laminating or bonding | Major |
| Print smudged or slightly off-register | Screen printing | Minor |
Chemicals, sourcing and packing
PVC covers can contain phthalate plasticisers, and rubber bladders and foams can carry PAHs. In the EU, REACH limits listed phthalates to 0.1% by weight in plasticised material and PAHs in rubber or plastic parts that touch the skin; see REACH. California may require a warning for DEHP; see Prop 65. Small soft balls marketed for young children are toys and need EN 71 or ASTM F963 reports. These are lab results; the inspector checks that the reports match the cover and bladder lots.
Hand stitching is often done outside the main factory. NITI Aayog counts nearly 20,000 household units in the Jalandhar and Meerut clusters. If your code of conduct covers home-based work, ask for the list of stitching centres; our factory audit records basic social-compliance observations but is not a SMETA or amfori BSCI audit.
Balls usually ship deflated and folded in polybags to save space, or half-inflated in boxes for retail. Folding PU covers in heat can leave permanent creases, so agree the packing method and check it on site.
What to put in your purchase order
- Ball type and size, with circumference, weight and pressure ranges.
- Construction: hand-stitched, machine-stitched or thermo-bonded; panel count; laminate layers.
- Cover material (PU, TPU or PVC) and bladder (latex or butyl).
- Any FIFA Quality mark, with the licence and model number it covers.
- Chemical test reports for cover, bladder and foam lots.
- Packing: deflated or inflated, polybag or box, carton count.
Leather cricket balls are inspected differently. Book an inspection in Jalandhar or anywhere in India.
Sources
- The IFAB: Laws of the Game, Law 2, The Ball
- FIFA: Quality Programme for Footballs
- Jalandhar district portal: Sports Hub
- NITI Aayog: Realising the Export Potential of India's Sports Equipment Manufacturing Sector (March 2026)
- Commission Regulation (EU) 2018/2005, phthalates under REACH (EUR-Lex)
- Commission Regulation (EU) No 1272/2013, PAHs under REACH (EUR-Lex)