FROM CORK OAK FORESTS TO THE WORLD, THE PORTUGUESE COMPANY SOFALCA HAS TRANSFORMED WHAT WAS ONCE WASTE INTO ONE OF DESIGN AND ARCHITECTURE’S MOST EXCITING MATERIALS.

ÁLVARO TAVARES RAMOS
Words

O Stool
Natural Black Cork
Designed by Toni Grilo

Pondering both history and sustainability, the founders of Sofalca spotted an opportunity to use cork oak branch bark, known as falca, which was produced whenever the trees were pruned or stripped.

In an economy where most people are looking for a quick return on their investment, planting cork oaks may seem rather odd, especially as it takes around 50 years for the tree bark to be usable for wine bottle stoppers. Pondering both history and sustainability, the founders of Sofalca spotted an opportunity to use cork oak branch bark, known as falca, which was produced whenever the trees were pruned or stripped.

"The family first got involved in cork through my grandfather, who collected it from growers and prepared it for the cork industry. However, it was my uncle João, a real visionary when it came to business, who convinced my father Ernesto and my other uncle Mário of the potential of falca, which is not suitable for cork stoppers", says Paulo Estrada, the company’s current CEO.

This was how Sofalca — a name that combines the words 'só' (only/just) and 'falca' (branch bark) — was founded in 1966, exploiting something that, until then, was used only as charcoal or firewood. The decision to set up a factory in Abrantes was carefully considered, with the region boasting a long tradition of cork production. The plant was also located next to a cork oak forest, which meant that raw material collection and transport was easier and cheaper.

Omega Collection
Natural Black Cork and Ash Wood
Designed by Toni Grilo

Ypsilon Collection
Natural Black Cork and Ash Wood
Designed by Toni Grilo

Apart from the occasional collaboration with architects and creative professionals, it wasn’t until Toni Grilo began working with Sofalca that design became part of the company’s DNA.

Sofalca’s commitment to social responsibility, sustainability and innovation gathered even greater momentum after installing the first mixed-fuel boiler in the Portuguese cork sector, following an oil crisis that had caused a spike in fuel prices. This change meant greater energy efficiency, replacing naphtha with biomass, while recycling a factory waste product called 'cork dust'.

This process produces water vapour at 400 °C, which is used to produce expanded cork agglomerate blocks. The high temperature lends a darker hue and helps the resin and cork granules bind inside the mould, creating a 100 % natural material, with no glues, paints or additives.

Apart from the occasional collaboration with architects and creative professionals, it wasn’t until Toni Grilo began working with Sofalca that design became part of the company’s DNA. "I was creating a lamp for Haymann Editions in 2013, which was made from different materials, such as marble or polished aluminium. I also wanted to make a version in cork, which is how I discovered Sofalca. That was the first step in creating Blackcork, and us talking about this intriguing raw material", recalls the French-Portuguese designer. "I remember Paulo having serious doubts at the beginning because the cork was black and had an unusual smell. Being positive, I said that it possessed a unique scent and wasn’t black, but more of a chocolate brown".

Frame Console
Natural Black Cork, Lacquered Steel and Tinted Glass
Designed by Toni Grilo

Tosco Suspension Lamp
Natural Black Cork, LED Lamp
Designed by Toni Grilo

Exo Mirror
Natural Black Cork and Glass
Designed by Toni Grilo

After the first experiments and prototypes came the Blackcork brand in 2014, which is currently one of the benchmarks of cork product design. "The collection’s first objectives involved changing Blackcork’s image, as well as focussing on the factory and Sofalca, which was a very interesting challenge. It’s somewhat of a hidden industry. The raw material itself was always invisible and undervalued. We took its essence and presented it to the world. All of this was achieved with 100 % Portuguese raw materials, manufacturing and design", says Toni Grilo.

Every effort has been made to create furniture and lighting that is aesthetically pleasing, authentic and showcases cork’s personality. This is exemplified in pieces like the Omega chair, Frame table and Boolean lamp, where the black of the cork contrasts with materials such as wood, metal and glass.

The visibility that Blackcork gave this special material encouraged Sofalca to expand the use of black cork further, as well as setting up the Gencork brand in 2015, which produces wall coverings developed via generative design and advanced digital manufacturing processes. According to Paulo Estrada, "Blackcork and design allowed us to innovate in an industry dating back centuries. We made sudden changes and reappeared with a completely different product, lending new impetus to the use of black cork for insulation".

Due to a boom in construction and new cork applications, the future is looking bright for the cork oak forests of Abrantes, as well as for Sofalca’s businesses and brands. "We’re currently in a transitional phase. We’ve presented black cork. It’s become accepted, appreciated and sought after, inspiring us to invite international designers to work with this very Portuguese material and demonstrate its immense potential to a wider public", says Toni Grilo.

Cork of Gold

FROM CORK OAK FORESTS TO THE WORLD, THE PORTUGUESE COMPANY SOFALCA HAS TRANSFORMED WHAT WAS ONCE WASTE INTO ONE OF DESIGN AND ARCHITECTURE’S MOST EXCITING MATERIALS.

Pondering both history and sustainability, the founders of Sofalca spotted an opportunity to use cork oak branch bark, known as falca, which was produced whenever the trees were pruned or stripped.

Apart from the occasional collaboration with architects and creative professionals, it wasn’t until Toni Grilo began working with Sofalca that design became part of the company’s DNA.

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