Matthew Gay
On our trip to Italy, to compete at the World Helice Championship in Ghedi, we had the opportunity to spend a day with Paulo and Elena Zoli at their factory in Gardone Val Trompia, Brescia. As we drove north from the city of Brescia up the scenic SP 345, this historic valley came into view with breathtaking terrain and architecture. This is the proverbial holy land for shotgunners around the world, many of the world’s finest makers call this valley home, some for centuries.
The Antonio Zoli factory is situated just off of the main road running through the valley at 39 Via Giuseppe Zanardelli. A couple buildings make up the campus of Zoli Antonio SRL, with the main factory and a couple of outbuildings where fine wood blanks are cataloged and skilled engravers turn steel into art.
We were met by Elena and Paulo, big smiles, wonderful Italian coffee, and a grand welcome to a company which takes great pride in building a family atmosphere to foster ideas and innovation. Fortunately for us, Zoli had another American customer on site for the day to build his dream shotgun. Not only would we have the opportunity to tour the factory, but also a chance to observe the process for a custom order.
Paulo sat down and discussed the details of this customer’s order, confirming all the options and elements to be included with this shotgun build. Once completed we accompanied them to the warehouse to select his stock. Pallets and shelves of highly figured walnut blanks were displayed in this atmospherically controlled room, each bearing its own unique character. A spritz of alcohol on the respective stock blanks is necessary to reveal a more precise view of the figure contained within the grain. After multiple spritzes and options, the customer chose his perfect blank which would be hand delivered to the stock maker immediately.
Paulo walked us out to another outbuilding where two master engravers were hard at work on different projects. The environment in this space was much more that of an art studio, than of an industrial workspace. Music played in the background and the lighting was drawn down to an optimal level for these artists of steel, silver and gold.
Giacomo’s Stockmaking Shop
All of us hopped in Paulo’s vehicle and drove up the valley to Giacomo’s workshop…an office with perhaps the most beautiful view of any on earth. Paulo, Giacomo and the customer evaluated, tested, adjusted and re-adjusted the measurements of this blank to ensure precise fit for the customer. Giacomo employs traditional stock fitting and making techniques while his wife performs the intricate checkering functions on his stocks. They are clearly dedicated to both the craft and the lifestyle of the industry which was born in this very valley they call home.
Break in the Day
This being our first trip to Italy, we discovered that lunch time is taken very seriously and serves as an opportunity to refresh and prepare for the second leg of the workday. Paulo and Elena took us to a wonderful restaurant at the edge of a very beautiful crystal-clear river on the south end of town. The excellence of the meal was only surpassed by the company and conversation. We had the opportunity to learn more about the Antonio Zoli company, family and history.
A New Stock and Back to the Factory
After the wonderful fellowship and meal, we traversed up the side of the mountain back to Giacomo’s shop to retrieve the stock, which was about 70 percent complete, lacking only finish, checkering and a butt pad. I was amazed at the speed and accuracy with which Giacomo completed this stock. With a double check of fit completed, we returned to the Zoli factory to tour the main manufacturing floor.
It was immediately evident that Paulo invests heavily in technology. Not just the equipment that manufactures the components, but also the machinery and computer technology that verifies exacting quality control standards. One of the first rooms we entered housed multiple large machines which had the task of verifying the quality of various components of each gun produced. A quick demonstration of the equipment showed the level of accuracy Paulo and his staff at Antonio Zoli demand of each product they create.
On the manufacturing floor, we observed precision cutting machinery which created dedicated parts for their firearms line. Paulo is clearly a purveyor of data. He shared that they run these machines at a much slower cutting grate than they are capable of, so they do not add any undue stress to the metal, maintaining the highest quality finished component with unmitigated structural integrity. The size of the initial raw steel block was quite impressive when compared to the finished part. Paulo shared that the best portion of a forging or billet was contained within the center of the block. Waste material from the billet is necessary to achieve the best final component possible.
Zoli still employs olde world craftsmanship techniques in conjunction with their technology. Some operations within the manufacturing process are better completed by hand and although they could be automated, Paulo’s focus is quality over quantity. Many of the delicate final fitting functions are handled in this manner…with file or chisel, powered by a skilled technician.
For those of you who have read my many gun reviews, you know I believe the quality of barrels to be perhaps the most important factor in the performance of a shotgun. Zoli builds, regulates and finishes the barrels of each shotgun completely in-house. The quality of their barrels is one of the things their brand is known for. Paulo invited us to view a barrels in various stages of production and the decades old equipment where the proprietary magic happens. While the soldering/joining machine is probably older than anyone reading this article, it has been continuously upgraded and maintained to utilize new fuels auxiliary controls, culminating in what many consider the very best barrels available.
While regulation and secure joining of barrels is vital, the process does not end there. A proprietary, precise honing machine runs nearly 24 hours per day, slowly lapping and polishing the interior surface of the barrels to exact specifications. Again, while the machine is perfectly capable of higher production speeds, Paulo runs this machine at a significantly slower rotational speed. This theme was consistent throughout the factory, with an ethos of quality and precision over quantity.
Maintaining and Building on the Legacy
Antonio Zoli can find its earliest roots in the gun making industry dating back to the 15th Century when they supplied firearm parts to gun makers in Magno, Italy. In 1845 Giovanni Zoli produced a flintlock pistol, which the family now holds in its private archives. Zoli manufactured rifles, shotguns and pistols continuously up until the beginning of the Second World War, when the Mussolini regime shuddered operations to supply their war effort. After the war, in October of 1945, the modern company was founded by Antonio Zoli and grew rapidly, transitioning from a small shop to a major player in the sporting arms world. The most recent evolution came to fruition under the management of Paulo and is referred to as “Revolution 4.” The technological advancements in design with the employment of the Boss style locking system and other technical features, most commonly found on only the highest grade of firearm, have become what we know today as the Zoli product line of fine sporting and field shotguns.
After a full day immersed in the world of Zoli, we sat down in the conference room to pontificate about all things. Paulo articulated both his vision and philosophy when it comes to his products. Building new technology focused not only on production but, most importantly, on the very best quality available, is the Antonio Zoli ethos. Corporate investment in this technology and employing novel processes for the production of the Zoli line, ensures the heritage and legacy established by members of the Zoli family over the past five centuries.
My wife Cheryl and I would like to thank Elena, Paulo and their staff at Zoli for their amazing hospitality and a wonderful time together in the beautiful valley of Gardone Val Trompia that Zoli calls home.
Zoli International is the purveyor of the Antonio Zoli line of firearms in the United States. To find an authorized dealer new you and peruse their full line of products visit them at: www.zoliusa.com
