Sails of change: John Cachia on craft, competition, and carrying a legacy
For over 40 years, Action Sails has shaped Malta’s sailmaking scene with a blend of tradition and innovation. In this exclusive interview, head sailmaker John Cachia shares how offshore racing, modern materials, and sustainability are influencing the next generation of performance sails crafted in the heart of the Mediterranean.
For over four decades, Action Sails has been synonymous with excellence in Maltese sailmaking. Founded in 1981 by Anton Cachia, the family-run loft has grown from repairing windsurfing sails to supplying and servicing yachts across the Mediterranean. Today, under the helm of his son John Cachia, the loft continues to balance traditional craftsmanship with cutting-edge innovation, servicing everything from classic cruisers to 100-foot offshore racers. In this exclusive Skipper interview, John shares insights into the evolution of sailmaking, lessons from offshore racing, and why sustainability and adaptability remain key to the craft.
You continue the family legacy as the head sailmaker at Action Sails, which your father, Anton, founded in 1981. How have sailmaking technologies, materials, and client expectations evolved since then, and how have you adapted the business to stay at the forefront of sail design in the Mediterranean?
Sailmaking has undergone significant evolution since my father established the business. He began by crafting windsurfing sails, using Dacron. At a later date, Mylar came onto the market. Since then, both the materials and the technology behind sailmaking have advanced tremendously, and the innovations continue to push the boundaries of what's possible.
As materials evolved, we adapted alongside them, always staying in tune with the latest advancements.
Initially focused on making and repairing windsurfing sails, my father noticed the growth of the yachting industry in Malta. As demand for yacht-related services increased, his attention shifted, and the business gradually specialised in the servicing of yacht sails, boom covers, and more.
Today, that progression continues at the loft, where we meet the growing demand for high-quality sail products made from the latest materials, such as hi-tech laminates using carbon and Kevlar fibres. As yachts get larger and the racing sector pushes for cutting-edge sail technology, we remain committed to providing top-tier products at competitive prices.
At the loft, you craft new racing and cruising sails, specialise in repairs, and offer spinnaker socks, electric winches, and rope. Could you walk us through how you balance traditional sailmaking craftsmanship with the integration of modern technologies and fabrics? What's your approach to innovation in the loft?
As mentioned earlier, staying ahead is essential. Every project presents its own unique challenge, tailored to the specific needs of each boat. For example, we might supply sails for a classic yacht, incorporating hand-stitched traditional fittings, but still integrating modern techniques and materials to ensure optimal performance. Specific mast base covers and wheel covers, made from leather, require the precision of hand stitching to maintain both quality and durability.
We have also had the privilege of working on some of the world's most high-performance yachts, including some of the largest, which naturally come with massive sails. In these cases, the challenge often lies more in logistics – figuring out how to manoeuvre the sails around the constraints of our loft to perform the necessary work.
We have decided to offer a selection of ropes as part of our retail range, as it is a natural complement to our existing products. Not only is it an excellent fit for our customers, but we also use specific diameters ourselves, making it an easy decision to add them to our services.
You've competed successfully in high-profile races, such as the Rolex Middle Sea Race (notably winning aboard Artie in 2011), and in double-handed events alongside Jamie Sammut (e.g., with Unica). What lessons from offshore racing—regarding sail handling, preparation, or resilience—do you bring back to your loft and your clients?
I have been fortunate enough to race alongside some highly skilled local sailors and on competitive yachts, which has been an invaluable learning experience. These races have taught me a great deal, both tactically and through observing how sails perform in a wide range of wind conditions. This firsthand knowledge is essential when advising clients. It also plays a key role in sail construction, knowing, for example, where additional reinforcements might be needed or how to shape a sail to optimise performance for a specific boat. Some boats are designed to perform better upwind, while others are more suited for off-wind conditions. Understanding all these technicalities is crucial in creating the right sail for each boat.
One has to keep in mind that conditions in the Mediterranean differ significantly from those in the larger Oceans and can be pretty unforgiving. The wind can change from 5 knots to 30 knots within a minute. Sails have to withstand a wide range of conditions, especially when it comes to local racing. All this must be factored into the design process.
Additionally, with the increasing UV exposure each year, UV protection has become an essential part of the sail, particularly for cruising sails that remain rolled or left on the boom for most of the year.
Your company supports both local and international sailors in achieving their goals. Can you share a memorable client case—from a performance upgrade to a technical repair—where a unique sail design or tailored service made a real difference on the water?
A high-profile job that stands out is a repair we did for the 100-foot yacht Comanche. They had ripped their Code 0 during training before the RMSR. This particular sail was probably the most essential sail of their "wardrobe". Obviously, my concern was whether the repair would hold, given the enormous strain on this sail. Not only did the repair hold, but they used it for a large part of the race, breaking the record and winning the event overall. It was a very proud moment for me personally.
Malta is a vibrant sailing hub, with events such as the Ragusa Weekend Trophy and the Malta-Syracuse Race shaping the regional offshore scene. How does the loft engage with this community—through regattas, partnerships or initiatives—and what future role do you see for Malta in Mediterranean sailing?
The loft has always been dedicated to providing the best support for cruising and racing boats passing through Malta. With its strategic position, Malta will continue to play a crucial role in Mediterranean yachting, and we are committed to providing an exceptional service on the island in any way we can.
With growing attention on sustainability in sailing, especially concerning materials and production processes, how is Action Sails approaching environmental responsibility? Are there innovations in eco-friendly sail fabrics or loft practices you're exploring or plan to adopt?
Most sailcloth today is made from recycled materials, especially for cruising sails. Whenever we replace sails, we always make an effort to avoid discarding the old ones. Instead, we look for alternative uses for the material, giving it a second life whenever possible.
For over 40 years, Action Sails has shaped Malta’s sailmaking scene with a blend of tradition and innovation. In this exclusive interview, head sailmaker John Cachia shares how offshore racing, modern materials, and sustainability are influencing the next generation of performance sails crafted in the heart of the Mediterranean.