Acetate, Bananas, and Chico Science

The ABCs of Polysom, Brazil’s only vinyl pressing plant



Rocha made it ten years before delays, technical problems, canceled orders, and diminished demand pulled the plug on Polysom. Buoyed by the rapid growth of new vinyl purchases in the U.S. and Europe, however, the owners of Brazilian independent label Deckdisc purchased Polysom in 2009 and reopened it the next year. Evangelical music was out and a Brazilian record collector’s wet dream was in: “Classics in Vinyl,” featuring remastered versions of Ultraje a Rigor, Titãs, Jorge Ben Jor, Tom Zé, Secos & Molhados, Rita Lee, and Chico Science e Nação Zumbi, among others.

In 2011, they are still going strong, and on a typically hot Rio weekday, I took the decrepit commuter train from Central do Brasil station out to Belford Roxo. Far from Rio’s postcards, the train trundles past seemingly endless favelas and into a poor suburb whose biggest claim to fame is a minor league samba school, Inocentes de Belford Roxo. A short motorcycle taxi ride from the train station leads to Rua Prudente de Moraes, a dusty unpaved road not to be confused with the luxurious promenade of the same name that runs parallel to Ipanema Beach. At the end of a row of modest houses capped with corrugated tin, an auto body shop, and some corner bars whose patrons are working on their 10 am beers, about the last scene one expects behind the nondescript gray façade of #101 is a 180-gram repressing of Nação Zumbi.


But it’s out here, where the urban periphery of the Rio mega-city begins to melt into the countryside, roosters crow, banana trees grow, and vinyl is cut to exacting specifications. João Augusto, who came to meet me from his office in glitzy Barra da Tijuca, is adamant that Polysom’s product is up to the snuff of the northern hemisphere plants in the U.S., Germany, and elsewhere that set the global standard. In fact, Polysom only went full steam ahead with 2011’s reopening when they compared one of their records with one from Bill Smith Inc. in the U.S. and saw that the two were of identical quality. That now places them in the proud company of only a dozen factories worldwide that perform the complete process of acetate, plating, and pressing.


João Augusto, an ardent defender of vinyl, attributes much of this to the “genius” who he kept on board, the aforementioned Nilton Rocha. While the modest technician demurs when asked if anyone else in Brazil knows as much about the vinyl fabrication process as he does, one only need look at his workshop—where he hand makes parts that are no longer manufactured—to know that one is in the presence of a true master at his craft. While João Augusto refers repeatedly to the “magic” of Polysom and describes it as the “fábrica fantástica” in an almost Willy Wonka tone, the seeming alchemy of acetate is quickly demystified by a handful of dedicated and knowledgeable employees who bring a perfectionist’s eye to the process from acetate cutting to plating to final pressing, explaining to me in Portuguese down to the details of egg white proteins in the chemical mixture. And all to a swinging soundtrack of Brazilian classics—during my spin through the acetate room I was treated to “Homem Gol” on the master control panel by Rocha’s son, audio supervisor William Carvalho. I later passed by stacks of Jorge Ben Jor’s África-Brasil and was greeted at the entrance by a jukebox soon to be stocked with Polysom’s catalogue.


“Vinyl is fundamentally a tactile, visual, and audio experience,” declares João Augusto, sounding like the consummate vinyl junkie. He is prepared to discuss the finer points of 130 vs. 140 vs. 180 grams, argue for the richer sound in the uncompressed vinyl format, and note the return of vinyl in an increasingly digitized world.

As Polysom owner, he sees potential growth from Japan, whose mania for all things Brazil would lead labels, in his opinion, to produce their vinyl in humble Belford Roxo. South American neighbors Argentina and Chile both have fervent vinyl cultures that also offer markets outside of Brazil. Inside Brazil, whose labels generally turn to the Czech Republic, vinyl is also a creative response to rampant music piracy—it’s much harder to find an official CD than a CD-R copy—which João Augusto rails against in his capacity as a label owner. Polysom’s next step is to begin offering picture discs and colored vinyl.


In a growing sign of vinyl’s foothold in Brazil, Polysom will open a temporary store in the Cidade do Rock, the sprawling venue for September’s Rock in Rio IV.  With seven days of music spread over two weekends and featuring a roster of international pop and rock headliners as well as Brazilian favorites, there are some oddball predictions that it could be the largest music festival ever.  At the very least, the 100,000 tickets per day sold out at lightning speed.

Unfortunately, the brutal economics imposed by Brazil’s staggeringly high import taxes necessitates passing on the cost of materials to the consumer. The average new, domestic LP in Brazil runs for 75 reais ($47). Perfection most certainly has its price, but with disposable income rising vertiginously and a consumer class conditioned to high prices for imported goods (which, for a while, almost all new LPs were), there is certainly a growing legion of Brazilian record nerds eager to plunk down a 50 real note and take home 12-inch of national pride, with Brazilian music that can finally read on the back: Fabricado no Brasil.

*A Chilean record label, Discos Río Bueno, kindly pointed me in the direction of Retroactivo, which runs a store and pressing plant in Mexico City. They specialize mostly in indie, psychedelic, and punk, and I decided not to fan any flames between Latin America’s lonely vinyl producers by testing the waters with João Augusto’s opinion of their product.

Gregory Scruggs is a freelance writer, DJ, and urban researcher who lives in Rio de Janeiro. He focuses on the intersection between audio culture and urban space.

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